I have really started to like sand as a substrate, buy I will not be able to stir it up to avoid gas build up. Buy, I have never noticed this as a problem. Should I worry? Just go with sand, it stuck with gravel?
I forget the math and important values at the moment to make a sound scientific statement right now. I think I've posted it in the past on here. In a nutshell, so long as you keep the sand bed depth reasonable (no deep sand beds like you might find in reef tank), you can't produce enough toxic gas within the tank to be of concern.
I like a lot of rock in just tanks. I could place rock in the tank, not any rearranging is going to be next to impossible as I will not be able yo reach the bottom. Issues?
"I could place rock in the tank, not any rearranging is going to be next to impossible as I will not be able yo reach the bottom." - I've read that sentence 5 times and am not sure what you're trying to say. It sounds contradictory. If you're unable to reach the bottom, I do think it'll be close to impossible to rearrange.
As I will have a little of rock in the tank I will not be able to vacuum much of the gravel. This is not much of a problem in my current 6' tank as I rearrange every couple months. I vacuum the entire tank at this time. I winter be rearranging the new tank very often.
Water current will be your friend in this situation. FWIW, have you seen any DIY jet systems on any forums yet? Essentially it's a maze of PVC hidden under the substrate with jets that shoot out in strategic locations and are powered by powerheads or larger submersible pumps (including the pump that's running your sump setup if you want to get creative).
How do I even get things in and out of this tank? The "grabbers" will work for small stuff, but what about a 10lb rock? 40+lb rock?
Drain at least 1/2 the tank, get a ladder ...

. Sounds like fun. I'd be extremely cautious of what you do put in there in terms of fish because they'll be even harder to get out unless they're large enough to be caught by rod and reel.

To save on buying some rock, what can I use as a base to pile the rock on top of? I was thinking of building a base of PVC... like a cavern of PVC tunnels.
Not sure how high you're looking to go, but IMO ultimate height depends on tank width to safely build up the base. You could use a marine expoxy to help stack if necessary, but rearranging would be a huge PITA. IMO a styro/cement style background would be best - Steve has some great threads on here already about those!