I've been thinking about making one too, except I don't see the point in making one unless it's manufactured using primitive means and naturally occuring materials so I've set myself quite a challenge!
I've done plenty of research on the subject. It seems that ignition is much easier to achieve with narrower bores, say 6-10 mm in diameter. Probably, the smaller the better but you also need room for your tinder. As regards length, the recommended length is usually 4-6 inches. As regards a minimum length, I really have no idea, but I imagine that below 4 inches might be pushing it.
I've a few problems to solve before making a primitive fire piston. Firstly, plugging the end of the tube properly so that air can't escape. It seems that air will leak through most wood plugs. Perhaps pine-pitch would act as a better seal?
Secondly, it's tricky to carve the piston to fit the bore nicely, say from a hazel rod. Carving a nice neat recess for the gasket is also tricky to do by hand.
There's definitely quite a bit of skill required in making one of these primitively. I've decided that elder is the wood to use for it as the pith can be easily removed and then the bore can apparantly be widened and made uniform using horsetail and then polished to a shiny finish by burnishing.
Anybody else have any input?