EDIT : NOW FOR SALE.........
If you're going to invest a great deal of time in this sim (and let's face it, time is the greatest investment ANY of us can make), then surely it's worth spending a few extra bob on having nice colour manuals and being able to sit down with a cuppa while you inwardly digest the incredible amount of information contained therein?
I simply uploaded my PDF manuals to http://www.fileprint.org/uk/index.php and specified the quality of print and the weight of the paper. Within a few short days, the manuals arrived on my doorstep SUPERBLY printed and presented!
I then took them down to my local Staples Store and they bound them with steel-wire spiral binders so that the books can be opened at any page and laid flat on a desk.
Because of the number of pages in the "realistic" manual, I split it into three books. Chapters 1 & 2, Chapter 3 and Chapters 4-9. Staples finished each one off with a tough plastic front cover and a heavy guage card back cover.
Don't ask me how much - just upload your files, choose the quality and the price will appear. It's not exactly cheap, but it is fantastic quality!
And no, I don't work for them :). In fact, there may be other companies who are much cheaper. Might be worth shopping around or simply contact your local printing company asking them for the cheapest way to print a colour document from a PDF file.
Tom