Someone should start a poll! Data would be interesting, and maybe useful to WotC.
After two months, with a lot of referencing and character designing, I've got whole sections of the PHB completely fallen out.
Sorry that I missed this question. The cost to laser cut things and remove the binding was around $6. The cost to make two spiral bound books was $15, so $21 for everything.
I went to a local (non-chain) print shop to have this done. I've heard both good and bad experiences at Kinkos and similar chains.
I'd recommend finding a place and bringing your book in. Tell them what you want done and have them explain how they'd cut things up for you. Decide from there.