The aircraft was originally built around a Volkswagen engine however, they were underpowered so the alternative was found in the Continental O-200 as 100 hp engines were determined to be the minimum appropriate horsepower.
Larger engines are used on some models however, builders should always consider the impact of weight on performance. That being said, close attention should be paid to the impact on the cowling shape if bulkier engines are used.
The average cost is around $20 thousand, then add the cost of the engine however, there are builders who have built their aircraft for less and a few builders who have built very nice show planes costing $80 to $90 thousand.
Yes, all models offered in the past and new models in development are being re-evaluated for the possible use of all composite or aluminum construction. ***Updates will be posted. ***
That answer is never simple as there are numerous factors that determine the build time. That being said, it might take around 1500 hours to build depending on the builder.
Unfortunately, we are not able to offer that service at this time. We recommend joining a local Experimental Aircraft Association (EAA) chapter for assistance and education.