thanks for your replies. From my limited research so far I'm looking at dealing with Flight Deck Solutions, a US company. They have supplied replica parts to boeing for the 787 roadshow, I haven't been able to find out to what extent though, but yes IPR could be a hurdle aswell. I'm still not 100% sure on the costs, i based my 'guess' of 200k on the other aircraft FDS have on offer.
CASA would be the certifying authority, there are other more retail based companies in Aus that CASA has been able to certify for procedural training, i need to check what level they have been able to achieve, but this looks like it shouldn't be a major problem.
Based on the replies I think its a good idea avoiding flight crews as an option for initials etc, but i will seriously look into what I can offer for the engineers, and assessments, thanks for that suggestion.
I'm not sure on data set, I haven't looked into that yet, any suggestions would be appreciated.