ORIGINAL: TLH101
One other thing you may want to consider. If you think you may be selling a model you are building, thing about shipping. Shipping rates have become very high, and can put an otherwise "goog deal" out of site. If possible, make changes to the build that will allow more disassembly of a model, such as removeable, or plug-in stabs, and 2 piece wings.
Terry,
That is a good consideration. It would be easy enough on a lot of models to leave the wing halves separate and not install the stab until I am sure where the plane would be going. Pretty much at the same stage as an ARF comes out of the box.
For those discussing making a living off building, that is not at all what I am thinking about. I already make a good living as a consulting engineer, I don't need another job. What I am looking at is financing my building habit by selling off models as I finish them. If I can get kit cost and material costs covered by a sale, that means I am building for free. That's kind of like free drugs to a junkie in my case...

I would get to build models for no out of pocket cost, which is a great deal to me.
Good points about building what I am interested in instead of what I think would sell the best. I will keep that in mind if I get to selling stuff off. I do this because I enjoy it and have no interest in simply building whatever for pay. That would turn my hobby into work and I am not interested in that at all.
The Ultrasport 40 and 60 idea is a great one. Instead of kits, I would be tempted to get set up with a laser cutter and get ribs, formers and fuse sides cut to match the RCM plans and just scratch build them. They are an easy build and I know I could do that significantly cheaper than buying the kits.
I have also thought of re-engineering the Goldberg Extra 300 (which is a great flying model) with sheeted foam wings and airfoil stab, two piece wing and wing tube, balsa/foam turtledecks and balsa sides. I would use the CG canopy and aftermarket cowl and LG. I am sure I could get that down around 8lb with standard balsa and probably 7.5lb with contest wood. I just don't know if anyone would be interested in it anymore. The market has kind of split around that size of model and there isn't much demand it would seem. Maybe with bigger control surfaces as a 3D machine it would sell. The basic design is a very good platform for either precision flying or 3D, depending on how it is set up.
Thanks for all the replies, there have been some very good points to think about.
Mark