Hi James, you seem to have covered most my points really and seem to be doing the same basic thing that I'm going to do.
I've messed about with the neck a lot to see if it's going to hold tension and it's pretty stiff neck, doesn't seem to have any give on it which is always encouraging. I'm going to probably end up using 100 gauge for the bass strings and 40 gauge for the octave. Hopefully that'll balance out that way.
Banjo tuners are a good idea for the octave tuners, especially on a 4 in line headstock but mine is a 2x2 headstock so I held one of the spare guitar tuners I have around against it to see if there was enough space and hopefully there will be. Tight squeeze but y'know...
You say about separate saddles being better for 100% perfect intonation but as long as the the intonation is 95% there with a pair on each saddle then I'm sure it'll be fine. You'll have to let me know how it goes when you put the knurled saddles on the bridge. If it's only a cocktail stick distance that's needed between the strings the that should essentially be 1 slot between them on a knurled saddle. Still,
The only thing I'm really not sure on is the top nut. I'd like to know peoples (and your) ways and measurements on the spacing on the top nut. How far between the strings in each pairing then how far between each set of strings over the 43mm nut.
Once I've got all decided, I'll add a build diary to the page on here.