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Even though the Vans is a simple plane and Andy says you don’t need to be an engineer, the work requires patience and a meticulousness I know I don’t possess. He mentioned a typical recent task: positioning the tailplane so the holes to secure it could be drilled in the rear fuselage. Thereafter the tailplane was detached and stowed away again. Heck, if I’d managed to attach it I sure as hell would be disinclined to take it off again. But lack of space forces many space-saving measures.
As to being meticulous… he showed me a discarded fuel pipe. In bending it he’d introduced a tiny kink which he couldn’t live with (“I’d know it was there.”). Of course, it makes a difference when you know you’ll be flying the plane yourself. Another encouragement is that each finished sub-assembly must be professionally inspected before it’s all put together.
Total cost? Earlier, when interviewing him for a website I run, we came up with: “the price of a mid-range BMW”. Now, he shrugs his shoulders. “Let’s say one of the cheaper Aston Martins.” And there’s another vital ingredient: a radio tuned perpetually to Radio 4, according to a mate who was helping.