>Battery drill in the vice one hand on the speed control
>one hand for the tensioner

Probably better off with an egg-beater type hand drill, it will be a lot 
more controllable.

Rather than using ones fingers to provide the tension, it is probably better 
to make some sort of clamp or V block lined with a suitable fabric to run 
the wire through. The friction with the fabric adjusted to get the right 
tension before starting winding. Then the layering of the wire can be done 
by moving the bobbin side to side to keep the wire straight through the 
tensioner.

But as the inductor is for a flyback arrangement, can you not lower the 
number of turns, and use a TV EHT style voltage multiplier to get sufficient 
output voltage? It will use more components, but the increased 
reproducibility of the inductor due to using thicker wire may well be worth 
it, along with lower volts/layer requirements. 

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