Well, I did a book version of my Voy/SW xover to send it off as a bday gift with A5 paper and they came out to about 125 pages with your normal card type paper for back and front cover, which bounded fine. The binding costs me about $5 to $6, but it's A5, not A4, though I'm thinking the length wouldn't really matter. As for photocopying, depending on how many pages you need some places might be able to do bulk discount for 5c per page. My old work place does that. :)

Since I still haven't got off my arse and read those 2 fics (Rodney and John distracted me), I'm in, and depending on when it comes out, might just pick it up from you or something. ;)

And hey, you need a cover image at least! :P