Got a response from Ed about the sporting use exemption for big bores, here's what he said
"Shotgun calibers are exempt from DD rules in the law,
IE it must be shotgun style case with the standard base size
for that gauge, straight sides .
Any length ok as long as straight to be sporting.
You CAN'T take 40mm necked down to 12ga and get automatic
exemption, it isn't shotgun style of a case.
Paper, brass, plastic, plastic or paper with metal
basecup, aluminum, steel, etc ok.
For rifle cases over 50cal the old ones before 86 are
grandfathered in, and new ones you apply to the
ATF Tech Branch for sporting use exemption. JDJ,
AHR,myself and others have done this. I did it for my 700s
and 585s. To apply you send sketch of case with dimensions
saying it is to be used for sporting uses, such as target
and hunting, and will be used in break actions, falling
blocks, bolt actions, lever actions and similiar actions.
And they will approve it for sporting use.Ed "
Looks like a pretty simple thing for someone with the skills to design something both big and new.