So my questions is, is it that much more expensive to make a .38Super instead of a 9mm? I'd love to have a Range Officer in .38Super, but SA doesn't seem to want to do that.
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Not much difference in manufacturing costs.
If SA won't make what you want, you can do it yourself.
The main differences between a .38 Super and a 9mm are the barrel, the ejector, and the magazine.
Fit a .38 Super barrel to your 9mm, Either shorten the existing ejector or replace it with a .38 Super ejector. Use .38 Super magazines. Instant .38 Super!!!
The extractor may or may not need a little tweaking, the recoil spring will probably be OK, but you are going to replace it at some point in the future anyway.
Put the original 9mm barrel back in, and you have a pistol that uses readily available cheap training ammunition. I only do this for range use, as the shorter ejector theoretically could cause a reliability problem. It hasn't yet though, so I don't see it as a problem.