This book is around 2 kg, octavo size, with 1/16" Lexan covers and could probably stop a handgun round from all the plastic. Project Gutenberg version!
The title was etched entirely by hand with a sharp needle.
Cover detail. The dedication is written in invisible ink :p
11 pt Palatino spaced at a relaxing 1.2 lines printed on transparencies. Aggressive kerning and hyphenation limited to not more than 1-2x a page. Widows and orphans controlled as well, of course. The book is pretty much unreadable despite all this unless you get a blank opaque backing sheet.
Side-sewn in sections of 20 pages with 25lb fishing line, all by hand. It's loosely held to the spine partly to help lie flat and partly to preserve the clean outer cover look. I considered using a clear epoxy for the cleaner look but didn't have the budget or time to try it, and it would have interfered with the book lying flat. A die cutter would have been nice as well. And living hinges with a more flexible cover material... and printing in UV ink so it's clear without a blacklight... and clearer transparencies... and holographic title etching...