I know we've talked from time to time about something else printed that's related to Dudeism. I was thinking something along the lines of a 6"x9" (15cmx23cm) up to 8"x10.5" (20cmx27cm) little thing that has articles just about odds & ends and shits & giggles. The print cost of something like that with 32 pages would about $3.47 plus the USPS shipping. (A bit less if we let the printer put their ad on the back or one of the interior pages.)
Another possibility would be do to something in Google Currents. Albeit Currents is uglier than an armadillo's nutsack, but it's free and has one hell of a distribution. Current Producer (the site to make them) is not very user friendly but doable.
Just a random think.
8)It would be a friggin' hoot to have a printed Dude magazine. Just sayin', though the internet paper is cool.