Hi! I just joined and happened across this posting... and it's great! I am a graphic designer for a profession, and have worked on board games, but have yet to take on the task of an RPG book (although it is in the works).
I have to say, there is nothing more nerve wracking than sending your stuff to print (and overseas to boot), I would have crapped my pants if I couldn't get the proof to see, but at least you got to see a digital proof! I struggle daily with printers here in the US trying to find a way to get costs down so I can do things locally to press check. But, alas, there is no hope for short run items. And it sucks that short run is anything under 10,000 units in this industry. Seriously? I wish there were a printer that would start a business for small run items (board games, books and collectable card games, maybe even comics) and figure out a way to accommodate all the short run needs in one large project to optimally run their machines.
Anyhow, great post. I totally relate to your experiences. And the books look great!
Tricia
Painted Horse Games
www.paintedhorsegames.com