If you're stuck on 55nm just sell the S1 underclocked and let people build up their 1GH/W hashing power from smaller cheaper units. 
Underclocking the S1 doesn't decrease the production cost. All it does is decrease the effective $/gh and makes them less appealing. If buyers are stuck on GH/W then they should underclock the S1 themselves.
You need to underclock the frequency and volts together (to balance H/W errors). But really I'm saying the the new 55nm chips have the same size package so just stick them on the same boards/chassis that everyone knows and loves. It makes no sense to re-design everything into a big silver box. Just sell 100GH/100W units @ 0.5BTC. If someone wants 1TH they can buy 10 of them for 5BTC and you ship it in one big cardboard box.
I don't necessarily agree that you need to reduce the voltage along with clock rate to balance H/W errors, but that's beside the point. It's not a "new" 55nm chip, it's the same as the old one.
The S1 is not datacenter ready and not everyone wants to hum and haw about what PSU to buy and how to arrange/contain units for acceptance into Colo. You can likely already achieve 1W/GH with the S1, but again, that doesn't reduce the production overhead so you're not going to see such a reduction in price just because the working HR has been reduced.
what's your address?
