Jones, the value of a prepurchase inspection cannot be overstated - it can help keep you from those costly repairs you speak of.. but soometimes they're unavoidable. An overhaul, for instance: Lycoming has a 2,000 hour TBO on most engines; many go beyond the time limit and the calendar limit (8 or 10 years IIRC)... I've worked on engines overhauled 30+ years ago that still run fine.
If you have a partner in the plane, it halves the cost of expensive surprises.
But a Cessna 150/152 rudder should not cost $6000 to repair. I bet you can get a used one from a junk yard for less than a grand. If you've got an A&P, you should have the stills to perform the basic upkeep on a plane. Just know when to farm out stuff above your skill level (I, for instance, have overhauled engines before but won't touch avionics) before your mistakes get expensive.. in terms of cash or life.
As for the cost issues.. Can't speak there, that's not my ball of wax. I'll let the instructors weigh in there.
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