If your images are all your own & you haven't borrowed anything from other art, you only need to file the Short Form VA with the copyright office (takes 5 minutes to fill out, add your $30 check & a copy of your deck & mail it off). If you used other art in some way, you need to use the long form & have to follow the instructions explaining what was derivitive. I submitted the forms in end of Dec., the check was cashed in March & the form finally got back to me in early July, so they have a 7 month start-to-finish time at this point. 9/11 put them really far behind, they have to have extra security on packages coming to the copyright office & that slows things down a lot. It used to be less than a 2 month wait.
I used a printer, local. They did all the cutting (sides match up perfectly) and such. But very few have lamination capability (or that spray varnish feature). When it comes to the card stock, feel for how stiff it is, you can't go by the # number. I came across firmer 60# weight than 90#. If you want 150#, which is really nice, they'll probably have to order it--but make sure their machines have rollers that can pull that weight through & not jam in the process. You'll want to look at digital vs standard printing with color separation, also.
When I did both decks I documented the printer problems/questions in the thread. They could do it via the art on CD, but could work with regular hard copy originals also. Prices varied at each of the 9 places we went to so definately check around & describe what you want, they'll give you a quote. If you want to see what I went through with the printers, check on this board for the threads 'One MORE Deck Hits The Table' and also 'Chat du Marseille/Cat of the Marseille'. We hit some snags, but the printer worked it all out.
I'm checking out a different printer for the next deck, I just found out Julie Cuccia Watts had her Blue Moon printed up over in Waukesha & they had the ability to do lamination, which she was very happy with. I DO want my decks to feel like the real thing, not just regular card stock.