1) "eddybo" , right now it seems that the ATF is taking their sweet time with getting our paperwork processed , I've seen it take just 2 weeks and as long as 2 months a few other guys that are looking to build their own its taken around a month.
2)The only reloading I have done for the 300 whisper was on a 11.5" AR and the loads were supersonic with 110gr V-max , haven.t messed with the subsonic loads in this case.
3-4) I would say that optimum barrel length would be 16" that way your not having to pay another $200 and another form 4 to get a short barreled rifle registered. The little 221 case and the big 30 cal bore make it a pretty efficient round , of course a little longer barrel isin't gonna hurt you as long as you use the fast pistol powders , if you use the slower rifle powders you will gain velocity and bring you up into the supersonic range so then you have to drop some powder weight to bring the speed back down.. You have to use such low load density because your using very fast powder , you want the majority if not all of the powder burned in the barrel that way your not getting any excenssive burn in the can itself which is the reason that guys use the pistol powders rather than the super slow rifle powders., that brings back to the barrel length issue , if you can get 1050fps with 10grs of powder in a 16" barrel but the same load from a 24" barrel gets you 1150fps then you will have to reduce the load , this is good because you are generating less gas at a lower pressure for the can to try to bleed off which in effect will technicaly make it quieter.
Now a sub sonic bullet shot from a 16" barrel out of a well made suppressor will not be any louder than the same bullet at the same speed out of a 30" barrel becasue a well made can is desgined to bleed off and suppress MUCH more gas and pressure , what it will allow you to do is use a smaller silencer because its not having to do the work that it would on full house 308 ammo.
Any subsonic load fom a well made closed breech gun are going to be very quiet , maybe as loud as a low power bb gun or slingshot , you will be able to hear the fining pin drop and the sound of the bullets inpact will be the loudest thing.
Shoot full house 308 ammo from a bolt gun through a good suppressor and the noise will be about as loud a regular 22 long rifle load from a bolt rifle , a high power pellet rifle , generaly not as loud a smacking two small pieces of 2x4 together, and the noise is comming from a differant action than the actual gun shot , the noise is comming from a tiny sonic boom that make is very hard to pinpoint the noise if you more than 50 feet away especialy if your infront of or the side of the gun.