buytradestuff wrote:
I'm trying to decide on an ideal volume size.

I see you have about 25 issues per volume. I'm guessing that's about 600 pgs each? What would you say about thickness of your volumes? On the shelf, they look great. Not too thick or thin.

At this point I don't have a preference on size, but since I get to make these custom, I want to narrow down my preference. 
I tried to average between 22-25 issues, which ends up being 1.25 - 1.50 inches wide when bound (including front and back cover of the volume).  I removed all back covers and double-sided ads, and page size/type varied a ton over the 30 year period, so i didn't really focus on page counts.  In the cases when there wasn't a clean end point for a story/arc, i'd just stop the volume at the desired thickness.  In every case, i thought the books were pretty manageable to read/carry, although even 1.50 inches with heavy modern paper can feel a bit on the heavy side.