You aught to see fountain soldering
Think wave soldering where the entire board does not have to get whetted by the molten solder.... Little ultrasonic transducers in the solder bath actually cause little fountains of solder that selectively splash the board.
Kim, I wish I could bring my fast turn prototype guys to bear on a project like this... I researched doing so for MP when he was pursuing the MP5.
FWIW, my companies' large-scale production operations can stuff something like 140,000,000 discreets per month, and the fast turn lines can push out a multilayer mixed signal board in no time at all. The website does not do justice to their capabilities, as their non-automotive stuff is pretty damn nifty (think Hughes Aerospace ground station hardware, among other things.) http://www.stoneridge.com/product/trans.aspx
--Edit... left unsaid above WRT MP5 is that my fast-turn guys can't be bothered for external stuff unless it's in 250-1000 finished boards at a whack. I can (and have) made some nifty boards in much smaller quantities but thats' for prototyping boards for $4M+/annum SRI sales.