Water cutting can be pretty cost effective, someone on here will be able to draw something up in some CAD voodoo.[QUOTE
I would love it if someone made a high carbon steel rotor for a mtb. Similar weight, lots stronger for impacts, and much higher friction coeffecient with most common pad compounds. I run these on my moto (which are surprisingly hard to find) and they're wicked. If rust is an issue, coat them before you install them and let the pads burn off the coating on the braking surface.
Then, group purchase.