At what point does AWS not make sense vs. having your own in-house metal?
Is it a simple metric such as 1TB / month of EC2 (without S3, etc.)?
Is it a bandwidth issue?
When does it make more economic sense to purchase metal vs. hosting on AWS? (sysadmin, access and infrastructure included)
If you know you need a server or two with a certain amount of RAM and HDD space, then rent a server or two at a high-quality DC like SoftLayer or Rackspace. It'll be cheaper, and you might be surprised how many "instances" worth of performance you get out of a single real box. You can treat those servers the same as virtual servers in every way -- they just take 2 hours to "boot a new instance" because someone has to build and provision it to your account at the DC.
You don't need to buy your own hardware and colocate unless you have specialized hardware needs.