Why the hang up? IME, many homebuilts are about as well made as a Yugo or Trabant, and a lot of licensed aircraft maint people share that opinion. Few 145 repair stations will even touch a homebuilt. A nearby shop owner has a oft repeated phrase. “Homebuilders are the only people I know that can screw up an anvil”.
Now, I completely agree with your reasons for building vs buying. AND, I have seen some very well made homebuilts. But they seem to be a minority.
I think many of the folks who opt to build, are really getting in over their heads, even with the fast-build kits.
Years ago, I decided to help some homebuilders with their projects. I have 10+ years of structural repair experience and about every sheet metal tool known to mankind.
What I found were people who thought building an aircraft was no big deal, because they were a successful doctor/lawyer/pilot, etc. Few had any engineering or aircraft maint experience. Their arrogance prevented them from acknowledging their lack of knowledge and building skills. I swear, these guys would buy a do-it-yourself brain surgery kit, just because they had convinced themselves they could do absolutely anything.
I found most projects in a pretty sad condition. Fabric surfaces you could poke your finger through, steel frame fuselages “welded” by dropping hot slag into the joints, riveting that was beyond horrible, MLG and wing attach points with severely elongated bolt holes, all manner of automotive parts slapped on, etc.
What really blew my mind, was these folks felt the kit instructions were merely suggestions, and they made all sorts of mods to make their aircraft unique. One guy replaced the copilot seat with a 30gal plastic fuel tank. I asked him what happens when a hard landing cracks the tank and he has all that gasoline on the floor and running down the skin to a hot exhaust stack. He just shrugged his shoulders.
I tried to explain the problems I saw, very diplomatically, but these folks wouldn’t listen to me or anyone else. And they refused to redo work they had “completed”. I gave one builder a 3-page letter describing all the problems I saw, and ended it by saying if he tried to fly his aircraft, he would die. Didn’t change his mind one bit.
I think it should be mandatory for newbie homebuilders to view 25 accident reports, complete with big color photos of shredded and fried homebuilt pilots. Perhaps that will help them appreciate the potential consequences of their undertaking.
Tony Bingelis has written a number of do-it-yourself books for the homebuilder. While they are quite helpful, they reduce many tasks to the simplicity of building a go-cart. I think this convinces people with negligible mechanical skills that they CAN build an aircraft. In addition, if you follow much of his advice, it WILL take you 11+ years to complete your aircraft. His suggestions, like using an oversize drill bit to debur holes, help reduce costs but substantially increase build times.
I went to the local EAA meetings, and the arrogance there was incredible. Few had actually completed an aircraft, but just a minor experience in helping build one was enough to make them experts on aircraft construction. I offered to help on several projects, but some folks were reluctant to show their work, probably in fear of exposing less-than-stellar workmanship. I eventually gave up on the homebuilder scene. If I ever build one, it will be for myself only.