A fine idea, ShadowSpark - I like it!
It leaves me either wanting to use a full leather wrap-around cover, and stitch that along the top and bottom - leaving more of a slide-case, where I wouldn't have to use any adhesive to directly attach the leather to the covers. The other option for that is to leave an exposed groove on the inner edge, so that the inner covers could also function as a pocket for fans' letters, photos, or other such things.
The other option is to have the inner side of the covers' end-papers inked, drawn on, or painted with his disc design - and have that aligned as closely as possible with the disc on the outer cover.
The innermost page I did want to have set with a message (likely in calligraphy) to both the fans, and to Disney (or whatever official gets their hands on it once it's shipped). I'd have to run through a few drafts here, and we can choose something meaningful and appropriate. Likewise, the end page would also have a closing message.
I'd settled on the book having ~96 pages. It's my hope that they will be filled accordingly - and I'd gladly make another book and send that off, if it's required, or if there are enough participants that more would be demanded.
Preferably I'd have at least two books in active circulations, since it would take any fan at least a couple of days to contend with travel, photos, messages and other matter. I'd assume that any fan would use at least three pages of space in the book (verso-recto), if not more. I'd actually based my calculations on six pages being used. In any case, each book would supply an estimate of about 20 participants.
Making the book thicker is an option, but the more something is sent about, the greater the chances of something bad occurring. Hence wanting multiple books in active use - then they can all be collected again once complete, and set as a full set to Disney.
As for the Comic-Con activism, I share your opinion. I am also not familiar with the legality of such things in your country; can you really be sued for promoting a cause? If there are no actual sales of material, I don't see how there should be a problem. I'd gladly make items which are to be handed out for free!
But, yes, until someone has concrete plans for doing so (I'd thought of putting forward the idea also), I'll easily do all else that I can. And when the day comes that we can have representatives to attend a Con and stand for Uprising there, I'll gladly contribute all that's possible!
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