I'm a cheap a$$ and partially just made a Gemini-SW Frankenstein. Just tested it last week and it works great, even took it to -110m and no issues. Tested it in a dual CCR configuration as well with a Triton as the B/O unit and this is a very nice streamline dual CCR setup. Once I get some more long runtime dives on it in open ocean to make sure I am fully confident in it ill take it cave diving.
For the head I was lazy and just bought the Fathom Sump SW heads (already has the HUD wired in with a nice battery compartment, has JJ cell connections fully potted in and glanded to a AK 4pin) so to save some time and headaches I went off the shelf route for this. I really like the way Fathom has made these heads and think it is the upgrade that the SW needed.
For the canisters I basically just copied the SW canisters but fully machined out of delrin and made them a little wider and little taller, I can jam about 3.8kg of sorb into both of them. This is what I was shooting for as I want long run time capabilities. And for those wondering for WOB personally I don't think there is a difference between this and the SW but for the Gemini I have no experience with so I can not compare.
For the counterlung I have no clue how to make these and did not want to try so I bought a spare SW one off a friend for $200 and I doubt I could make one for less than this as I would have to somehow find someone that could vulcanize/fuse bladder material and trust that I would hold, get the outer Codura shell custom sewn up with nice zipper in it too, machine the canister fittings and glue them to the bladder. Also for those wondering yes I did cut a hole in the CL and added a OPV/dump valve on it.
I had a spare JJ DSV so to save on money I just used this and conveniently the Fathom off the shelf loop hose for the Gemini fits perfectly over the JJ DSV ends and the HUD holder "almost" works.
For the plumbing I have piles of Apeks regs so I just threw a plug/cap in a DS4 and found some LP hoses in the pile of hosing that was close to the right length, and I actually have 2 needle valves laying around (an old Chris Kennedy one and one of those KISS "top secret" clicky ones) right now I am using the clicky one since it is a dual MAV.
For the computer I just plug in one of my Petrel 4 Pins from another unit, same with O2cells, I just throw cells in from one of my other units.
Fathom Head - $1,900
Fathom loop hose - I think it was around $50
Used CL - $200 + Piranha dive DSS OPV assembly $25 + hole cutting kit from ebay $15
Canister - $800
Misc final fitment stuff; small LP fittings, loops weights, clips, bands, bungee, etc. - $50-$100
The rest of the stuff I already had and its parts I use on my other rebreathers.
Total cost around $3,100
My only issues I have at the moment are I wish I would have made the canisters flat on the bottom to make it easier to fill them (did not think this one through very well) because right now I need to put them in a little plastic bucket thing to hold the canister upright so I can dump sorb into them. But this is an easy fixe once I get some free time ill just make up a 3d printed stand to hold them. Also the Fathom HUD cable is to long, you have wrap it around your loop like 4 times. The threading on the "towers" to connect the loop hose to the head I would have gone with a little bit coarser thread, the current thread takes forever to fully screw on and not the easiest to start if your just gorilla man handling it. Later on I might play around with something different for this, first prize would be if I can fit some kind of iQsub bayonet type fitting there but at the same time for now this unit is just for fun and I am trying not to sink tons of money into it.