Roger wrote:Over the past two years both production and shipping costs have continued to increase...
For publications such as this book, going with some of the new "print on demand" vendors would eliminate a lot of headaches.
I've helped someone publish a text book using one of these services, and found the process not much more demanding than setting up for a print run.
What you do is to create a PDF with particular settings (all explained on their site) and they take care of everything. They even handle the orders, so there's no need to run your own shipping.
Some vendors have a human in the process, which is great for quality assurance, but costs a setup fee. Others are fully automatic (no fee).
I've used one of the latter (blurb.com) and we're very happy with the results. (I haven't used their "easy" book creation software, because PDF gives me more control).