Well, I've tried a couple recently, and they haven't met my (admittedly high) standards. I think what's going on is that I'm not organized enough, so I'm going to try to write down all the steps and where I'm trying to make alterations.
First: tear the paper down to size, or cut it. (I can cut paper now! Maybe I exaggerate a little. Blade still needs sharpening, and I have to strip a bunch of paint before the various cutting guides work properly, but whatever.) That part's pretty easy.
Second: make sure the signatures are folded properly. Which, if I had one, would involve sticking the mess of them into a nipping press. I've been using books and clamps and occasionally random marble tiles. Works pretty well, as long as I can be patient about it.
Third: sewing stations. Which means making punching guides - and I'm pretty lazy about those, most of the time, but since measuring with folded bits of paper is nicely intuitive, I've gotten better. The only time punching holes is a problem is when I don't have my fancypants wooden jig, but that's a simple solution: make a cardboard one for portability's sake.
Fourth: Remembering to put in the right kind of endsheets. As long as I'm
awake when I sew the books, this doesn't come up. It's just that I have a couple of textblocks I've sewn recently where clearly I
was asleep, because they are missing some weird shit. C'est la vie.
Fifth: sewing. I can do sewing. Mostly. It's very important to remember even tension. This is key. Beeswax helps. Loads. Using the right weight of thread is vital to my future happiness: if I don't, I get all crabby about how much the spine swells.
Sixth: Gluing up the spine. Well, this is where I really fell down on the most recent book: I forgot to put in a hinge under the paper spine lining. Next time I will remember, and there will be two layers, and it will be much more sturdy. (I will also use better endsheet papers.) This is where I need to remember to put in a ribbon bookmark if I'm going to be doing that. Also, it's probably time to stop using PVA and start using paste, because it turns out that non-reversible gluing is actually really frustrating.
Seventh: prepping the case, for case binding. Or whatever I'm doing with boards. My mistake on the last batch was to cut the boards the same size as the signatures. I don't know what I was thinking. I mean, not having squares makes sense given what I'm trying to go for, but not having enough space in the spine ... no good at all.
Which brings us to actually making the case: bristol or some other spine stiffener, and cloth. So I'm actually perfectly content with what I did with the bristol spine stiffener - it works really well, and I got the size right, even. On the other hand, I might want to try something more flexible, just to see what happens. I've still got enough bog standard book cloth to do a bunch more experiments, but I'm going to have to work out how to make my own soon - among other things, I have this awesome green fabric that really begs to be put on a book. Or in a quilt. Or both, preferably. I tried leaving just one board thickness between the spine stiffener and the board, which I think would work if the board was thinner, but I don't like it as it stands. Eh. The next one will be better.
There are a couple of aesthetic choices I need to make, but they're not a big deal. As long as I can make some interesting little books that don't cost too much, it's a success. (Well, once I've sold them, anyway.) If I can't do it with cloth covers, I can get back into making paste paper ... which I should do anyway, because as really freaking entertaining things go ... that's a good one.
In between all of these things, I need to refresh my memory on fancy bindings. I got some purple leather, and it cries out for something
wonderful. Or I could just get some wooden boards and make Byzantine-inspired books. Which also seems like a good idea. Give me a couple of weeks to think about that.