You could always ask the firearms safety authority, this should be right up their alley.
Speaking to a chap I know who used to do this sort of thing in the NZDF, he said it can get pretty involved, but here is a few things you could do:
Shorten the firing pin,
weld the firing pin hole up,
Pin/weld the action so it can't be cocked,
drill a caliber sized hole at the commencement of rifling,
Plug the bore (tight fitting rod and welded)
remove the sear.
I guess it just depends on how far the cops and firearms safety authority want you to go.
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