| Paul,
Sounds similar to whats happening where I am but for 41,000 users, 1 org but around 150 servers, about 50 domains etc, so need to get a heads up, also using aelita, although what I have heard and seen so far is quite scary, not many peeps seem to rate it from what I have seen.
As for building etc, I've got some old kit I could use here at home, and I'm signed up to MS Action pack, so got more licensed s/ware than I can shake a stick at.
Like I said I've got some books coming, so will have a ganders when they arrive, and probably build a 2003 box running EX2003 also, and go from there. | 
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