Besides punching hundreds of domains into GoDaddy to see if their available, are there any tools to find EMD's?
Here's a method that uses GoDaddy but is maybe less manual than what you're currently doing. Start out with Google's keyword tool. Do a search on your seed keyword & then sort by local monthly volume. Select the column drop down menu on the right side & deselect everything. Then you can highlight all the keywords, copy them & take them over to http://www.godaddy.com/domains/searchbulk.aspx. Paste the results into the bulk registration box & check the .com, .net, & .org boxes & hit search. It will tell you have invalid characters. Hit okay. It will then show you which variations are taken & which are available.
there was a recent website I found called www.emdvault.com this looks like exactly what you are looking for. let me know what you think.