I decided to try out Lulu’s print-on-demand service as a cheap way of binding the (undefended) PhD thesis, and just got the books through, about one week later. I’m really pleased with the result, especially given each one only cost £3.75. I used the `Crown Quarto’ size stock to get maximum width for the margin notes, and the LaTex typesetting seems to have done the trick at keeping everything neat and well-spaced.
Will have to investigate hardback binding for doing the final version after the viva (and inevitable corrections).