(I am a writer with a completed manuscript that was picked up by Silven. Since they've gone under, I'm contemplating going it alone for the book, in case no publishers pick it up.)
Layout can range from $1 to $4 per page. How long it takes generally depends on the complexity of the layout--things like number of sidebars, amount of art, and so on. There's a fair amount of "up front" work in developing a template, but if it's done right then the manuscript can flow into the template without too much more formatting. If it's not done right, then it can get pretty tedious. If all you have is a manuscript, then you'll also have to go through the headache of finding artists and doing all the art direction. Then you'll want a website to support your title, etc., etc.
Yes, I'm trying to encourage you to shop around your manuscript instead of going it alone. Unless you want to give up writing to start running a business, you're much better off finding an established company to pick up your title. If you target the top 20-30 publishers at RPGNow, you're bound to find one that will pick it up.
Oh yeah I'm definitely looking to a publisher, but given the size of the book (300 pages, hard cover, black and white), and the fact that it's a campaign setting, I don't think it bodes well for the pickup. Granted, the setting already has a community of 1000+ fans, and I can get about 60 to 100 pre-orders, but I have not had much luck over the past few days getting it picked up. Couple of nibbles, but that's it so far.
Running a business doesn't scare me, given that I've got an MBA, and I already run a business that manages the Avlis servers. However, I have no expertise in the publishing field, which is why I'd rather get a publisher than go it alone.
Again, if not, I'll just keep preparing the manuscript one step at a time (i.e. art, editing, layout, etc.) and then going to print at lulu.com or something.
You might also want to check out Eruvian.com. The site allows gamers to publish their own homebrewed content, from individual characters, spells, and so on to entire settings - in a standardized, searchable online format. It also allows fans to contribute to the setting using those same tools, if the author chooses to allow it and with the author maintaining complete control over all contributions.
If you haven't heard about it it's probably because it just launched a couple weeks ago.
To the best of my knowledge, I've taken anywhere from two days' solid work to three weeks' occasional work to lay out the products listed in my .sig. I don't know if that helps. As I've gotten more practice with the tools I'm using, I find the total time I need dropping to about 5-15 minutes a page (I just can't be sure, I'm afraid; I've never seriously clocked myself). But I'm just freelancing, and learning as I go.
PrestO has the right idea. It is best to go with an already established publisher and work out a percentage deal based on actual sales of the book. Even small publishers, such as ourselves and 12 to Midnight, already has a stable of artists to draw from and the experience to do the layout with ease and quality precision.
Of course, this depends on your manuscript as well. When we did Mindcraft for Doug Meershaert, it was not too difficult or tedious but also not a walk in the park.
But there are a lot of good, quality publishers out there - so shop around.
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