Re: has never been done before
If you're counting Blue Origin's suborbital hops, then you should also count SpaceX's Grasshopper.
Refurbishment costs should go down as Block 5 comes into play. Block 5 is supposed to incorporate lessons learned from studying the boosters they landed successfully. They are currently on Block 3 or 4, and they've said they won't bother reusing them many times.