Get a decent kernel to start from, I would recommend anything UNIX, so you can port over utilities from Linux, FreeBSD, and the like. Linux kernel would work fine, but if you don't want to distribute source changes, use any of the BSD distributions (the code in there has a less liberal license, and is generally tidier to work around). Learn your way around the kernel, bring in utilities and programs (watch out which utilities you bundle with a BSD license, should you take that route; GPL utilities bundled in a BSD licensed OS might ruin privacy for you) and start writing your own bits and pieces wherever you need it. Learn how to use xlib (or create your own drawing library, it's up to you) and develop a window compositor. The possibilities are endless if you know where to start.
_________________ "That I'm in forum signatures is just a sign the invasion of sortie is nearing completion. Soon you'll all have to become me to defeat me." ~ Sortie
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