In 50 years of (model) engineering I have found that the most difficult job I have ever done is my current task of making and setting up the valve gear on my Bolton triple expansion engine. The machining of the expansion links was OK but getting the 'just right' balance between a running clearance being too tight or slack so that the die-block moves smoothly and the drag-link operates without jamming is not easy. Even neatly silver soldering such small items as the die-block is quite tricky. I think it is the small size and the demanding geometry of the gear that I find difficult meaning that multilple assembly and disassembly is required. I thought boiler making was demanding but this is on a different level.
So what is your most difficult job?