Actually, since you're already so far ahead of us blockmaker wannabes, why don't you try selling an Alu block making service? I mean, let the customer give you the design (you're not responsible for the performance that way), plus, if he doesn't give you a detailed measurement drawing, then you can charge for that service too.
You never know, you might even get DangerDen to ask you for some prototypes.
I really like your cost analysis. It would be nice to see the power consumption for Al vs Cu. The bit cost has to be a fair amount too.
I don't believe that an Al block NEEDS to be anodized, as long as the other components are Aluminium too. You could even put together an Aluminium watercooling kit.
1-Alu prototyping service, with optional draft svc.
2-Alu wc kit (sell it on demand only, see how it goes).
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