Getting ready to build a pair of killer 6BTA 5.9 12V engines. Has anybody ever messed around with putting 24V pistons in a 12V engine?

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You would be way better off doing a CR Cummins. 12 valves are literally stupid.

Pick up some Diesel Power magazines you will find plenty of vendors in there that can help guide you to build the right package. There are plenty of 12V motors making tons of power reliably, of course a 24V common rail is a better engine but won't be any cheaper to build or any more reliable, fuel burn will be nearly equal so don't know why you would need to spend the extra money. Why do you want to put 24V pistons in the 12V???

common rails have great technology, until you need parts and see that 2 injectors cost as much as a set for a 12 valve. but yes 12v are stupid. If mechanical injection is the route you intend to stay with I'd look into a 24v motor with a ppump swap (12v front cover, pump and custom lines)
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I question the mechanical pump in today's world, you'll have an engine that smokes like hell because you can't control any timing at all. 20+ years ago it was acceptable to be smokey (to a point) because there was nothing else.

One word of advice, no matter how much Hp you make you have to have prop speed at least as fast as the same Hp gas engine or you won't go nearly as fast, stick with the gas engine if you can't do that.

Proper tuning and reasonable hp can keep it from being a smokey pig.

my engines have mechanical pumps and don't smoke at all except for one puff just as the turbos kick in when i am getting on plane, and they didn't do that they way it was tuned from the factory, I made some adjustments to the aneriod and now it runs much better.

What do you have in yours?