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Excellent topic! One of my favorite experiences so far has been sampling vitolas from blends I like. Smoking your way through the base line Padron cigars gives you a great idea of how vitola can affect the experience, and the good thing with those is that they are all pleasant.
Edit to say the ambassador and delicias are my favorites.
Im just going off my experience with RYO so take it with a grain of salt. I think it really depends how the blend is set up. If your using half leaves and stuff its probably trickier to get right. But if its just the same leaf all the way through then the bunch is the same throughout the length of the cigar. When I roll a stick the blend is exactly the same whether its a robusto or churchill. Same number of leaves and all. The only difference is how much leaf I want to chop off when I cut the foot.