Made this a while ago with some rough price estimates. Check out
$250.00 Shipped Parts kit
$96.00 Shipped NDS 1-p Receiver
$25 Transfer fee
$25 Rivet sets (enough to build ten ak's)
$45 or so for the compliance kit. G2 double hook trigger, gas piston, muzzle brake
$2-3 for the trigger retainer spring.
.50 for the gas piston 3mm rivet.
The tools I used are the following. Please note a drill press is not needed but makes life easier. Especially when drilling the front receiver. I used a hand drill since I had left my press up north and one hole had to be egged rather significantly.
Northern tool 12 ton press. $89
A decent vise $25
Trunion hole locaters (tweezer style) $5
Trigger guard rivet jig (made myself)
5/16" carbide ball mill $25
Rear long rivet jig (made myself) maybe $5 in parts
Punch set from sears $12
Bolt cutter rivet tool bought this already made $50 (if you buy the 24" bolt cutters from harbor frieght you can make them for under $20)
Steering wheel puller from autozone to pull the barrel $20
Hardened all thread method to install the barrel $6
Head space gauges $60
Harbor freight cheapo drill press $60
I now build from flats which is much much cheaper... I scored a deal for 5 flats for $45 shipped. I borrowed a flat jig from the guys on akfiles.com and bent them up a few months ago. Building from a flat is definitely the way to go. I can now build romy's for under $150. (Use to be able to closer to $200 now)
Tooling up to build these is not cheap but a lot of the tools you should have or could always use for something else car related as well. If you plan to build only one ak (good luck it wont happen you will build more) building may not be the method to go. Check out ak-builder.com for already made tools at decent prices.
So with this build and new tools I bought to replace other tools I left in the move and including everything was just under $800. Not too bad since these cost around $700 to buy already assembled.
If you have all of the major needed tools you can build all of your own jigs cheap. I would say you could get away building an ak poly underfolder for under $500.