An instructional DVD I made on SEO for wedding photographers and their websites (http://photographyseo.com).
Recorded screen casts and mastered it in iDVD. Did a run of 1,000 at Discmakers for about $900. Sold out the initial run (@ $79 per disc) in under 2 years. Now we just one-off them or give them an option of viewing online.
Looking back (or if I do it again), I would probably do it as just an ebook or online videos to avoid shipping hassles.
Regardless, it's been a fairly easy ~$80k.
(BTW, if any HN folk want to see it for research purposes, let me know)