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I want to be able to field more than 4 honor guards and don't really want to buy more than one box of Calgar and friends and end up with extra Calgars. Furthermore, I don't want all my honor guards to look alike.

Any suggestions on what to buy in order to build extra honorguards (I am not against buying other model boxes in order to mix and match component to produce them)
I was thinking maybe the new Vanguard Veterans could fit the bill with some extra sternguards legs from ebay.
Any other ideas?

New sternguard all the way.

Easily one of the best new box's for SM.

Other option is the forgeworld route. as they do that the red scorpion honor guard kit. just scrape the icons off. and give em new heads and shoulder pads.
The Legion praetors are nice too.

I use these

http://www.forgeworld.co.uk/The_Horus_Heresy/Legiones_Astartes/Emperors_Children/EMPERORS_CHILDREN_LEGION_PALATINE_BLADES_SQUAD.html

Yeah, I looked at forgeworld yesterday and I agree that they have pretty nice models. I also like the scorpion honor guards a lot and, considering that my homebrew army is called the Iron Scorpion, they would fit very nicelly. As for the Emperor's children legion palatine blades squad.. wow, didn't notice them! Very nice models. I would just need to chop off the polt pistol hand and replace them with bolters from the sternguard box and I would be in great shape.

So Calgar and honorguards, a box of scorpion honor guards (even comes with a nice librarian) and a box of Palatine blades would give me something very nice looking.
Thanks!

You dont need to.

Honor guards come with both Bolt pistols and Boltguns.

For my honor guard I went forgeworld all the way. I started with MkII crusader armour, then picked up some of the command upgrades for the plummed heads and banners, and I got a special weapons pack. All this combined with any extra cloth bitz/purity seals you have lying around and its gold. I finished mine last month and they look amazing. Also, the legion champion makes a great chapter champion.