Oldman

You could always give it a try on a small scale using pre-orders.

Give folks an idea as to what, how long/pages, content, the specifc bunkai etc.
Give us a price.
Take orders and do a small "desktop" run for the folks whom paid up-front.

You should be able to keep the price point, pretty low--just time and whatever supplies you need to print off the copies you need.
And kinko's is not that expensive--just make the reproduction part of the cost.

Mainly the largest expense will be time and the first art--after you have that its just a matter of hitting "print" on you computer.

Format and binding of course are another subject.

You also might float the idea past the guys that run the site.
I noticed on the opening page that they do publishing now.

I will buy a copy sight unseen, I would think that other might as well.

As a matter of fact, you have ALREADY POSTED SOME OF THEM--so folks can already see what you are doing--might be able to post some of the pages on-line in read only format to give others a better look.

I think you should look further into it.