I'm not sure if this has been done before, but I'm pretty sure no one has ever done it to such an ambitious extent. Black Death is a professional-quality board game in terms of its graphics, but you download it and assemble it yourself. It easily matches off-the-shelf products, but at a fraction of the cost.
You can download the full rules, sample game components and the assembly instructions from the product link:
http://www.yourgamesnow.com/index.php?m ... ts_id=2084
Take a look at it, then come back here and tell folks what you think. Or better yet, buy it...