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You may want to try Amaya, the freeware browser from W3C. It has a "Make
Book" function that expands all rel="chapter" or rel="subdocument" tags. It
also has (limited) functions for headers and footers, as I recall. You may
just be able to create a single HTML file with rel links to all of the
individual pages, in the order you want them, and then just expand that
document.
You may also need to go in and build a little stylesheet for print format
documents with things like page-break-during: avoid; for IMG tags and so
forth. HTML is rapidly becoming viable for printed documents, and it's
certainly worth trying first.
You can get Amaya from http://w3.org, and feel free to email me if you have
any questions.
