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I am going to jump in here knowing next to nothing so excuse the very basic questions.
1. There are two patterns, Colt and Oly? Colt systems lock the bolt back and Olys don't?
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Yes, there are two major patterns. There are one or two other types that have their own system, but are 9mm only. Oly came out w/ their's then Colt did (from what I have read). The Colt system only locks back IF you are using factory Colt magazines and an adapter block that will activate the factory 223 bolt hold open OR you replace the 223 bolt open w/ a 9mm one. The diff. is a longer bolt open then w/ the 223
2. Does one need a special upper receiver to run a pistol caliber or will a standard 5.56 flat top work?
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A standard 5.56 upper rec. will work. The only difference is on the dedicated pistol is there is no forward assist and brass defelector cast into it. The pistol cal ones have a plastic deflector that is held on by the ejection port cover. And there is no gas tube hole. But they are essensially the same (It'll work).
3. After a bolt and a barrel the only other thing one needs is a mag block? to fit whatever magazine you are going to be using
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A stronger recoil spring maybe needed and/or a heavier buffer.
Oly makes a 40 Cal upper now. But the mags have a tube welded on so that no addapter tube is needed and you use the standard 223 mag release. I think Stens can be modified so that 40 will feed from them, so a SOCOM block can be used w/ unmodified Stens (but it uses a paddle release). The block is held in by the 223 mag catch, so if you forget, you drop the mag AND the adapter.
A Colt pattern 40 will be a CUSTOM thing. Custom 40 SW barrel and opening up of the 9mm bolt assembly. So it will end up costing a bit(?) more. There are a number of adapter blocks out there made to work w/ the Colt style. RRA, ASA and a few more make blocks. There is even one to use unmodified Uzi mags (it's been reviewed here, can't say I've read in to it).
The idea of a .40 cal upper is very nice as I shoot an STI .40 for IPSC so not having to start up a 9mm press is WAY appealing.
IPSC_GUY sends
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Again, the cheapest and quickest is to get an OLy 40 upper. But it has no hold open and you can risk dropping the block when using a SOCOM block. Don't quote me on what mags they use at this time. Hope this helps.
Edit- Kurt of Kurt's Kustom Firearms has made 40 and 357 Sig uppers in the Colt style.