Whats the problem with registering for VAT. Put your mobile bills, diesel, accountancy fees, etc through and reclaim the VAT. Makes commercial sense to me.
Also, as Gumbyman said, its more credible in current climate to be VAT registered and even more so, if through a company.
Revenue have rules (namely antifragmentation) which prohibit the avoidance of VAT registration through articifical methods such as Gumbyman mentioned. However, its more for connected parties, but Revenue could take the view that you should have been registered.
If Revenue were to form this view, and you never charged VAT when you should have, you are liable. In my opinion, it is always best to register and charge VAT (where appropriate).
I would say the big issue here is that if you are not VAT registered, Revenue will probably form the view that you are an employee and not self employed. This company would then be seriously exposed to PAYE/PRSI on the grossed up amount.