How about a composite bell housing?  I know you aren't a fan of
 composites for some applications, but the bell housing might be a
 relatively good one..

Matt-
Labor intensive.
 Might be OK if we had a mold.
 One could NC mill a 3D female mold.
The thing about an NC mill it works while you sleep :)
Paul Lamar

Very True, I've been doing this VERY thing for the last week.  I
start the mill up when I get home from the day job and shut it
off in the am when I head off to work.. I'm Finishing up a
composite Buck [to pull a mold off of] which won't need any hand
finishing when it's done.. simply wax the buck and splash a
mold.. I'll send pic's when I'm done.  It's a small one, less
than 15sqr foot area but w/ a 0.010" step over to finish [and a
nice slow 50ipm feed rate] it takes a while :)



Jarrett