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Most silencers are just simplifications, modifications, and upgrades to Maxim's original design, and some pretty good ones can be had for purchase pretty cheap, it's just the NFA part that costs and takes time. Constructing one might be a fun project, but it is likely to cost more, not to mention time and effort, than just buying one, although if the project is the objective, rather than having a supressor, who cares?

You might want to investigate your noise source a little more thoroughly, what you are hearing may have nothing at all to do with what others hear at any distance. Muzzle blast is a wierd thing, my DPMS A-15 with a crowned bull barrel makes an horrendous amount of noise at the control end, but a friend's similar one with a flash hider seems much less noisy to me, and his barrel is way narrower than mine. I don't think barrel diameter would have any bearing, I think it has more to do with where all that sound energy is directed.

I have audio frequency spectrum analysis software on my laptop, and have done a couple of comparisons during IDPA matches. Lacking a calibrated microphone and such, my comparisons are worth the paper they are written on, but I have noted significant differences in noise experienced immediately behind the shooter with different muzzle configurations.