Why is it 50 times the effort? The effort to make one coin is the same for you and the scammer.
Factor in the detailed and precise effort of counterfeiting the actual hologram. Imagine you have a hologram maker willing to be complicit. It's not like you can just scan the hologram into photoshop and hit print. There are three-dimensional details that have to be reproduced. Imagine you get even one minor thing wrong, or don't reproduce one of the deliberately placed mistakes in my hologram. All someone has to do is say "look on the XYZ side and if there isn't an ABC, it's a fake". What are you going to do then?
Realistically, these aren't getting traded around like quarters and dollars in commerce, they are being collected as collector's items and passed out to promote Bitcoin. I don't believe that will ever change, and the high premium cost is what will keep that in check. When trading Bitcoins face-to-face becomes popular, my vision is that people will not trade Casascius coins, but will "be their own bank" and print their own Bitcoin cash at home (File -> Print -> Print Money) instead of paying ATM fees, and people will accept printed Bitcoin bills sort of the same way the supermarket accepts home-printed coupons: by immediately scanning their QR codes, and in the case of Bitcoin, sweeping the funds in real time. After use, the printed bills are thrown away (or optionally reused if needed to give back change). The possibility of fake or duplicate or counterfeit bills will be completely controlled by the fact that the recipient who scans the bill will know within seconds or minutes whether the money was good - bills will only be accepted blindly (unscanned) from parties where great trust/recourse is present.
Let's assume your markup is entirely costs, that you make no profit at all. It costs you .31 BTC to make the coin, and 5BTC to populate it. It costs me .31BTC to make the coin and zero to populate it because I'm using the same 5 BTC over and over, and you supplied that too.
It must be possible to make them for .31BTC, because you're already doing it. Every coin I counterfeit therefore earns me 4.69 BTC. Every coin you make makes you zero (assuming a .31BTC cost of manufacture).
How long are you going to be able to sell it before people wise up and realize they need to up their vigilance a notch? Where are you going to sell it where you don't risk chargeback / recourse / getting your ass kicked? And when people realize you're up to no good, will you have scammed enough people 4.69 BTC at a time to pay for the $thousands you invested in your fake holograms that you can't move anymore now that people know your scam?
What if I go again but make fake 25 BTC coins?
You could, but those sell far slower than 1BTC coins. The economics are about the same - you'll net 5x as much from each customer you scam, but you'll sell way less than 1/5 as many, and will probably net the same profit before you're found out: likely not enough to cover your initial cost.
I don't see why it's not good business sense (assuming morality isn't a factor). Something that costs you 5.31 BTC to make, costs the scammer .31 BTC to make.
Because before you can make the first counterfeit coin, you have to invest thousands of dollars in the production of holograms. Producing holograms is very front-heavy on costs. They are cheap to run in quantity, but expensive to set up the design.