I was aware of registration free COM, and I did consider it, in fact I tried it out several times during the last decade.

However in my experience it was always hard to get working properly, and it was always poorly documented. I'm talking primarily about the XML assembly manifest, which is very easy to get wrong.

In fact I remember vaguely the only complete documentation & example I could find at the time was an article in MSDN magazine, but now I can't find it, only bits and pieces of information scattered around, nothing in MSDN except a vague article. Most references I can find are for consuming dotnet COM objects and I also need to consume components written in C++. So the situation has gotten worse, documentation-wise.

Another couple of points:

1) Personally I don't want to use COM at all, I think it's too complex. I think it's really a brilliant idea but wrapped with over-engineered, idiosyncratic idioms and API. I tried to distill it to the minimum required by me for my "COM lite" above.

2) I'm not the one creating those components, I'm in charge of the consuming application. The people creating those components (in house) are essentially my support people, they're not really professional developers, and get confused with anything slightly more complex than plain C++ code. None of them has ever learned anything about COM, I'm the only one who knows all about it. Meaning I have to support them when things go wrong with COM registration or when they compile their code and it doesn't work. So I'm on a mission to get rid of all COM dependencies in my application, and replace them either with plain DLLs with C API, or (in one specific case) with my "COM-Lite" I outlined above.

Wasn't there also a hacky way to achieve the same goal as registration-free COM even before it existed?

For in-process DLL-based servers, you could try to implement CoCreateClass (IIRC) manually and bypass GUID-to-server lookup and go directly for loading a DLL and calling the method for getting the object from it.

Probably, although I tend to stay away of such solutions, as they eventually turn into headaches to sort out in some machine, where the hack doesn't work as expected.