Well this is what I did - it was full of controvery when I did it but six months later, knock on wood my books are still intact.
I did away with the plastic sheet protectors.
:O :O :O :O
I went with a 10 point font, I printed landscaped instead of portrait (long width of the page) in two columns and I printed double sided (front and back).
I know, I know, I know. But I did.
It cut my book size down by about 3/4 for starters.
It cut my printing costs down about 2/3 (largely due to no plastic sheets.
It cut my time down from stuffing the books down to an order I can't even calculate.
My books, discs, and spare cables now all fit in a single plastic tote that I can carry all by myself - that includes an even dozen of books.
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I did that back in December of 2004.
I've had a couple of books doused real good with booze - but they have survived and still usable - printed out on laser not on ink jet I think helps. All 12 books are servicable still.
I also installed a blank page in the front and the back, for tugging, rubbing on the rings. What I've noticed is that having the books printed landscape seems to keep the pages from getting torn out from rough handling. Users hold the back cover up on an angle - probably because the book extends inward on the table - because of this the pages get turned about 75% on the ring, not 100% across. I also picked ringed binders that are larger than the print pages.
My library is 4000 songs, each book has by artist and by title -- I think there is roughly 150 pages in each book.
That's what I did - and I'll admit I'm surprised they have held up - but they have held up. My stuff gets fri/sat usage -- so if you're running five or six nights a week hardcore - well this may not work for you. I will keep printing them this way.
Of course now that I wrote this I'll have two books destoryed on Friday by having a pitcher of beer splill on them, one set on fire with a cigarette, and two ring binders break!
LOL