Why doesn't Kershaw have a custom shop? I think it would be really neat to have a 'build you knife' feature on the website.
Pick the knife style, pick the color, pick the blade steel, pick other options. Have all the selections modify the price accordingly, just like building a computer on a manufacturer website.
I'm guessing you do runs of various types, why not do an over run of the specific parts and add them to the custom shop's stock. If you are doing 50k carbon fiber inserts for SO, do a run of 10k more for custom orders. I'm sure people would gladly pay a premium to order it just the way they wanted.
I know there are people out there (myself included if my g10 Leek ever gets back to me) who are willing to buy multiple knives just to franken them together to get the knife they want. I'd gladly pay MSRP or even over to have the options instead of cobbling them together myself. I paid $75 for my s30v Blur. I would have paid probably another 50-75 for the carbon fiber Blur just to get what I wanted.
Kershaw can't make money putting one together in the configuration (or any configuration) for $125-150?
Musicman guitars/basses are made in specific combinations (number/style of pickup, color, string count, pickguard style etc) for regular production to go to stores. You can still order any possible combination your little heart desires (usually for the same price, you just have to wait). They still do one off/limited run/special edition stuff but you can mix and match anything that is in regular production.
I'm sure I'm not the first person to suggest this, what's the argument against setting up something like this?