Looking way into the future, I've been looking at the idea of putting The Gay Recruitment Squad into a box.
The Box Office will do A5-size rigid coloured boxes for 1.01p each, minimum shipment of 50 boxes. Add shipping (10 quid) and VAT and that leaves you with about 1.38 a box.
Because it's in a box, I figure you can get away with a lower quality rulebook. I'm thinking of my old Tunnels and Trolls rulebook: A5, cardboard cover, stapled in the centre, laser-printed.
Everything else is fairly cheap: laser-printed cards, counters, griplock bags.

