It's actually not that bad in most states, some even have exceptions to emissions requirements for certain classes of self-built cars.
Now, getting required insurance coverage, that can be a different story. Btu even there, many states allow you to post a bond in lieu of an insurance policy meeting state minimums.
Usually making one car, or millions of cars, is doable.
It’s trying to make and sell three or four that is nearly impossible.
Related: Local Motors
https://en.wikipedia.org/wiki/Local_Motors