Aerospace manufacturing is fucking wild and is a rabbit hole worth diving into if you’re looking for some of the finest engineering porn humankind has to offer.
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If an aerospace engineer made one of these he would no longer be an aerospace engineer.
Everything else you said is correct.
Aerospace manufacturing has a paper trail longer than you can imagine. The company selling this part can tell you (well, the FAA) the exact ingot out of the foundry and every single process and every person who has touched it since then.
No machine shop will take this job; the moment this guy is unable to produce a serial number and paperwork from an approved manufacturer (likely during preflight if not installation) the FAA will track down the owner of said shop. At best that owner will lose their business and pay a massive fine, at worst spend a good long time in prison.
The FAA doesn’t fuck around and for that I am thankful.
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Depends on how much effort went into reverse engineering the part, but most likely when tolerancing enters the conversation. Most machine shops aren’t able to hit those tolerances and would laugh you out of the shop.
A shop that can hit those tolerances will kick you out of the shop; there’s a good chance they already work in aerospace. They have a deeply vested interest in avoiding the accompanying FAA inquiry should it be installed or, Satan forbid, actually flown.
A non-aerospace shop capable of meeting those tolerances would start laughing at the desired price point. Purchasing a suitable blank alone would cost over $1500, much less cover the actual machining.