Hi Andrew,
CutePDF works pretty well. After a couple of trials and errors, I was able to print my first booklet. I also played around with the settings to print book signatures (which also works well). While this shows it is possible to print booklets and books at home, I have some concerns which cannot easily be overlooked. They are:
1) The effect of paper grain when using letter sized paper.
2) The suitability of laser toner for document longevity.
For paper grain, I have learned that the grain needs to run parallel to the binding of the book. Otherwise the pages will be difficult to turn and may even close on their own (mousetrapping). Given this information, I have concluded using common letterhead (8.5 x 11) sized laser/copier paper is not a good idea if the intention is to fold it in half to make 5.5 x 8.5 signatures. The reason is the grain would then be running in the wrong direction.
A better solution (for 5.5 x 8.5 signatures) would be to take sheets of 11 x 17 paper, cut them in half, then run them through the laser printer. This too is not without it's problems because the laser printer may jam while duplexing due to excessive paper curling. In fact, laser printer manufactures warn not to use grain short paper for this very reason.
I would be curious how people have dealt with this issue.
As for toner longevity, consider the following article:
https://netfiles.uiuc.edu/r-evans4/www/toner.htmlIn a nutshell it discusses the problems laser toner may experience if exposed to too much humidity or excessive temperatures. An example would be leaving a laser printed book in a car on a hot summer day. Doing so, may cause the pages to stick together or the toner to flake off the pages. Even sending a home printed booklet in the mail to a friend may result in problems.
Again, I would be interested in hearing how people have dealt with these kinds of issues.
vtbinder
