This has come up before, can't find it with search. I think the advice was to pay Mr Jim Rimmer to cut a set of punches for you. Seems a bit excessive when photopolymer plates can be used for letterpress q. inexpensively - maybe that's what your friend was thinking of?

You might try contacting the folks at SPEEDSPOOLS:

Harry McIntosh
SPEEDSPOOLS
385 Queensferry Road
Edinburgh EH4 7AG
Scotland

machot@supanet.com
tel +44(0)131 336 2849

Though they mainly convert Mac, InDesign and Quark files into Monotype sorts and cast hot metal, they may know more about creating/casting fonts from scratch. Mind you, I can't imagine that punching and casting a metal sort from a new source is anything but EXPENSIVE!
 

Found the thread - http://typophile.com/node/13887

Cheers, Si

I think a custom cut typeface is not all that expensive as compared to other things that are made for the individual. A custom built guitar isn't cheap. It's all a matter of priority. If a person is passionate about anything a higher price is not a hinderance.

Quite honestly I have never been asked to design and/or cut a metal font, possibly because it's assumed that the price is outrageous. Most things I produce in the metal foundry bring me about five dollars an hour. That stinks even in Canada, but I do it becuse it feels good, and I've been barred from the saloon and the pool hall.

Jim

"I’ve been barred from the saloon and the pool hall."

Jim,
I understand they serve beer at hockey games :-)

ChrisL

Chris

Yes, a beer goes well with a dooby and fights off the cold.

Jim