Here are some "A" version manuals.
http://www.ko4bb.com/manuals/index.php?dir=Tektronix/Tektronix_-_2445_Oscilloscope
If I can wait, these guys: http://www.bestvaluecopy.com/ do an excellent job printing. I haven't asked them to do engineering folds yet, but I was super happy with a 270 page full color manual with two inserted documents, one being a set of notes pages. Spring bound with clear front and solid back printed on 28 lb paper.
We had a minor communication issue since three files were included. Because of document protection, I was unable to combine the pdf's.
They don't have # of pages vs thickness, but certain bindings have thickness limits. Cost wise, it's not worth doing it yourself.
For smaller B&W manuals, I have done them this way: Print on duplex 28 lb paper all pages at 8.5 x 11. Then put on a flash drive the larger sheets and add them back. I have Staples print them, then I fold them and hand them back to be spiral bound.
I have yet to deal with the mucked up manuals with random pages inserted.
I did, but never completed a copy of a book bound A4 manual. I used the Staples copy machines with my own A4 paper bought from Staples and copied every single page on the glass single-sided with margin shift etc. My scanner broke, so i never finished the conversion.
11x17 or 8.5 x 14 pages can cost me about $1.00 each to be scanned. $20.00 min. charge. While U wait.
I went through a whole lot of experimentation to do blueprints and the most effective is to drop it off at a CAD place and don't put any time limits on it. Scanning to TIFF at a high resolution was $10.00 and $5.00 to print. They scanned when their scanner was not being used, Win-win for all.
Fed-ex and Staples don't have the expertise to do it right.
AT Fed-ex/Kinkos you can scan smaller documents yourself. NO ADF.