Above is one builders layout plan for cutting parts from sheets. Its not official, but a good place to start to estimate costs.
All the items in kit building apply here, but these are guys who took it to the next level and carved a plane out of bare aluminum. With little or no factory parts.
Scott Stewart`s 1st engine start on his scratch built CH-640. Proof positive you can create magic in your garage. Photo credit to him-On this page and the main page, its pictures of his wings under construction.
Dan Hill makes some great videos on scratch building his CH-701. His channel is well worth the time to educate yourself in the art of scratch building.
Greg is scratch building a CH-750 but his advice and skills are universal. His videos are worth a watch. There are too many good ones to post here.
Help for Home Builders has tons of interesting educational videos
and lots of other great YouTube videos