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@O'Shane
A bit before my time but I'm sure my brother will be able to help me with my research.
I agree you don't absolutely need 2 master cylinders just a larger piston than is standard for the caliper. I was thinking mini-moto/motor trials but haven't delved too deep into that yet. I know Hope do use different size pistons in their calipers and levers but I don't know it it's quite enough.
Balancing wouldn't be too difficult - you just need to choose two calipers with slight different displacement amounts. And a browse through an RS components catalouge can't do any harm. I have my cable dual brake set for the rear to come in first and lock. As you say, not that expensive but everyone seems to imagine that hydraulic = ££££
Same with the riding. I've never broken anything apart from a lever that was only after the bike took a 50ft leap through trees.