I think the cost really depends upon what kind of cluster you use.
There are three Saturn clusters on ebay right now for 30 bucks with free shipping. Many might say things like "that doesn't go past 100 mph, ect." but it would be virtually free to scan the display and print out one that goes higher.
Your real cost is the interface.
Certainly a serial connection isn't a requirement, but the gauges have to at least be digital.
Here's my train of thought on this one..... The avr route is certainly a good one, but the more complex the signal you have to send the more custom programming you have to do which makes it offputting for other people (trying to get a system in place for everybody, not just something for a personal project). Store bought AVRs certainly make things easier, but as you pointed out, it really ups the cost of the project.
So a parallel port interface would be cheapest. I know you are thinking that's outdated tech ect, but they do make usb adaptors like so:
http://www.ebay.com/itm/150938418139?hlp=falseYeah that costs a whole three bucks.
Even if the entire harness isn't serial, so long as the individual instruments are, it should be more than sufficient. I know for a lot of speedos/odos you simply "flicker" a pulse to the gage.. the faster the pulse, the higher the value. So essentially you need one data line per gage.
The parallel port has 8, so that's enough for:
Speedometer
Odometer
Rev Light
Temp Gage
Fuel Gage
Left Turn
Right Turn
And one bonus. Or if you want a simpler setup you can just do the speedo/odo and a rev light and have 5 outputs left over for vr buttons and a start button.
Of course all the gages have to operate at low voltages. If it's a 12v signal system, that complicates the build to the point of where symprojects stuff seems more cost effective.
Also if you want a shift number indicator that isn't enough outputs, but I never got that anyway. Can't you tell what gear you are in by looking when you shift?
So what I'm really needing is a source of cheap instrument clusters that everybody thinks looks nice and have low voltage digital controls. I'm not very knowledgeable in the auto parts department so I can't look at a random dash on ebay and say "yup that will work".
If we go for this very generic implementation I can probably make things universal with a simple calibration routine (adjust this setting until your rpm reads 10x100 ect...)