The problem with LBB size is that it is not a standard size anymore. Half-quarto is impossible to POD anywhere. Your choices these dasy are:
1. Digest size (5.5×8.5)
2. US Trade (6×9)
3. A5 (5.83×8.27)
The original LBBs are 5.67×8.78. The closest to that is probably 6×9.
Of those options, the Digest Size (5.5x8.5) may be preferable for an inobvious reason ... weight.
I'm thinking here in terms of longevity of product when used.
The saddle stitch binding will eventually loosen and come undone (with years of use).
A "lighter" weight of paper in the binding (because the paper size is smaller) will put reduced repeated stress on the binding staples.
Because the leaves of the paper are "shorter" relative to the binding staples, there is less opportunity to "torque" the pages against the binding staples, which would cause the staple holes to wear (and expand) over time, which will then cause the pages to "loosen" within the binding until the binding fails (eventually) with repeated handling and use.
Additionally, the Digest Size (5.5x8.5) will mean that you have "smaller books" (relative to the original print dimensions) which when printed en masse will incur less mass for transport purposes, potentially making shipping and storage "slightly easier" in a variety of ways.
For books which had higher page counts (LBB A3 Twilight's Peak comes to mind, immediately) the Digest Size (5.5x8.5) print size may help with the longevity of the books in print without becoming "too heavy" when held in the hand. Yes, the weight difference is going to be marginal per book printed, but when you have a COLLECTION of them, it's going to add up ... because "we make it up in volume" (or words to that effect).
- A recreated 1981 Classic Traveller Boxed Set with saddle-stitched books that are updated with errata.
THIS.
So much this.
Although, to be honest, if you're printing things in boxes, you really want to make the BOXES the collectibles to put on the shelf (and help keep things easily organized).
- Box Set: LBB 1-8
- Box Set: LBB S1-13
- Box Set: LBB A1-13
- Box Set: LBB DA1-8
That way, you don't wind up with "a dozen box sets" needing space on shelves (because: "gotta get 'em all!").
Yes, LBB1-3 are "all you need" to get started with
Traveller (in CT), but those books were just the START ... not the END. If anything, LBB 1-3 is more of a "teaser/taster" preview of the rules and setting(s) that you can make. They're the barest of bare bones to start putting flesh upon.