Printing cost is going to be tricky, though. Unless everyone from here is willing to give a little to the project, you could easily go under trying to self publish.
Ever heard of http://www.lulu.com ? It's a great website for self-publishing, and is most cost effective. The site prints it, binds it and then you get to say whether they sell it for you or not, and to whom. They just keep a percentage of the sales per book, or you can pay them for the printing and distribute yourself. Something to think about, though this topic is rather old.
There's the "super happy anarcho fun pages" way, where you put stuff out on the web for free printing out/viewing on the web. They do this because they want the comic to be free without going into debt.
im not sure if this whole thing is still on since no one has posted in a while but...
today i made a guitar pick out of a dumpstered cap to one of those plastic one-gallon jugs for like milk or water. its really "authentic". hehe. i dont know know if anybody else does this, but it just kind of came to me today
I'm guessing this never got off the ground. *sigh* so many good ideas when your drunk but then we dont even remember what we were so stoked about the night before....
You could use a website like lulu.com that's print on demand. Basically you upload whatever you want them to publish, and people can order them at cost, plus a small percentage fee that the site tacks on, and whatever royalty you set for yourself.
the SAS survival guide is a good outdoors DIY book.
anyone know in the first ramboo movie when he makes a trap out of sticks attached to a tree and kills a cop with it? well it's called "the pig spear trap" and that book shows you how to make it. it's real easy folks.
hmmmm....shouldn't people have to work hard & gain experience to obtain some of the more "secret" info yr proposing to include in this manual. Just seems like, while good intentioned, this DIY manual is more of a manual for the cops to find/catch us. Let's remember this isn't summer camp for some people.