Hey SlaveMason,
Yes, you are correct, a very long and drawn out process. I dont know really of any tutorials on making VC's and their parts.
What I do is make the entire model and the VC is built into it.
A tip is to keep a ruler or measuring tape in your desk drawer and use it often when making parts. If you know about how big a 'something' is, find the dimensions on the ruler and use that in your 3D design program to make the part(s).
You can also just about make 'everything' animate in FS in a VC, but note that in FSX you can only have about 246 animations or something like that. (240, 241, 246, I cant remember, just heard about it the other day).
Another tip. You can hide everything but the VC to work on it. Like the cabin (inner walls) and panel, etc. Learn to connect things per 'department' as Hierarchy so that you can easily hide / unhide entire departments, such as Cabin, Panel, airframe, pilots, engine, etc... That helps tremendously when making a big, sophisticated model.
Remember, on a Cabin (inner walls), you can see through the first side, so you are looking through it (if the outer his hidden). Easier to deal with. And if it gets in the way, just hide it.
Are you making this in FSDS or Gmax? Are you making this for FSX or FS9?
Bill