Hi Babalon Jones!
I would like to help answer your questions, but in the long run, I'm not entirely sure how helpful I can be!
I have self published (and in many cases, self printed) a couple of decks now. I am currently working on printing one as I type this.
Each one was an amazing exhilarating, frustrating, diabolical, wonderful, ultimately rewarding lesson in WHAT NOT TO DO.
I look now at each deck publishing project as something well learned, and if I was smart, I would have saved up enough funds to have someone I trust take care of all the printing and publishing and hassles. (and in a couple of cases I did do exactly that...but only after attempting to do it by myself.)
So I can tell you that there are many different ways to approach it. And yes...you can make a deck at the local Staples. I did that with my second.
But eventually I found out that these business copy center places really don't care for my project as much as I care for my project, and they will do things like discontinue the perfect card stock in the middle of a print run, so that half of a single deck will have stock that is completely different (weight & brightness)from the other half. And when you explain to them why this isn't good, they will stare at you like you are a bog beast from the planet Jupiter.
You can take things to a local printer. And if you find the right person there that you can trust, then you can get a decent product, for a price that allows you to have a decent mark-up for a limited edition art deck. But again...you have to make absolutely sure that they know what you what exactly, or you may end up with 5000 decks instead of 50 (I kid you not) or the wrong stock or miscut cards, or no color correction...or a half dozen other things that may be small to them...but HUGE to you.
(same goes with every Print On Demand internet site that promises quality card decks. Just don't do it. You will want to tear out your hair. Or theirs.)
I also know that there are large print houses that offer pretty good deals on any number of decks. I can see if I can scare up the info for you. Almost all of them will send you price quotes and samples of their work. And one of the ways to do this is to offer preorders, and use that money to finance the project. You will have to show off some images at that point though!
You can also print them yourself, in the comfort of your own home.
It's a nice option because you can control a lot of the artistic angles. But it's good to have someone else help with the unforeseen technical issues that WILL come up. Also, good to do your research first, before you say, buy an expensive laser printer that actually hates quality weight card stock almost as much as it hates printing double sided cards.
If you like, you can send me a PM, and I can try and answer specific questions based on my own experiences of what I did with my own six decks. If you search the creation forum here, you might also find the threads with info and issues dripping with the frustrations I was going through in the midst of each project.
Like I said...don't know if this helps at all. I would have answered you sooner, but my preorders just allowed me to get my electric and internet turned back on today!