Printing/format/pdf for emails?

Ok so I want to start setting aside money for printing this. how are we thinking to format/print this? What can we do with 8x11 papers? how do we keep the articles all together? Staples? Folding zine style? I like the allure of a "news letter," looks good when you post it on bulletins and such.
What about an electronic pdf version for mass emails too?

I will be meeting with people on Friday and Sunday to format it.