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How do I set the Round cap and Round join as the default line behaviour in Illustrator? Now when I create a line the cap is set to Butt cap and Miter join by default.

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With nothing selected, make the changes you want, save the file as a .ait template --- if desired, place the template where the default templates are --- on a Mac using American English that's:

~/Library/Application Support/Adobe/Adobe Illustrator CS#/en_US/

Adjust as necessary for how your system is configured.

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The Windows path is C:\Program Files (x86)\Adobe\Adobe Illustrator CS#\Cool Extras\en_US\Templates I believe. Though the Cool Extras bit may vary by version, I'm on 5.1. –  Johannes Sep 9 '13 at 18:42

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