I'm rearranging this just a bit for clarity. Responses below.

Skylune wrote:
And this is all perfectly legal under the FARs.

Assuming this ex-test pilot was in the US, no, all of this is definitely not
legal. Here are some illegal things this guy did, per Newps' description:

Newps wrote:
loaded it
up with so much crap that with a full tank and him on board he was 50
pounds over gross.

He flew the airplane outside of its operating limitations.

Took off on his first flight, no tailwheel time
by the way.

He flew a conventional gear aircraft without having a tailwheel endorsement.

Now he's rebuilding an Aeronca Chief.

He can only make major repairs or alterations if he's certificated to do so.
I guess he could be, but it sure doesn't sound like it.

Yoke won't smoothly go in and out because he has
stuff behind the panel interfering with its travel.

The aircraft was not in airworthy condition.

Opens up the wing
and screws a metal patch on either side of busted spar and covers it all
back up. Not even remotely airworthy.

Enough said.

Bottom line is, the necessary regulations are already in place to make
experimental aviation a safe activity, but there are plenty of rules in the
FARs that builders and pilots can ignore if they choose. Personal
responsibility is crucial.

Tom Young