...At what point does solo mining become worth it, when you can generate at least 1 block per day?...
At the point where your revenue covers your expenses without you being out of pocket (i.e., if you have a $2,900 monthly electric bill and BTC/USD is $2,900, then you need no less than 1 block per month just to cover your electric) and then the profit margin you want to have on top of that.