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I also made a hollowed out book as a case for my Reader. Rather than cut up a book that I might want to share with anyone else, I went to the library and bought one from the used book sale for 25¢.
It took a bit of playing to get it to fit well. It is actually pretty snug. I realized that pulling it out by the notch that I cut for the power button might put too much torque on it and could possibly break the substrate in the screen. I added a piece of ribbon that lays under the Reader to allow ease of removal. I retained the first few pages so that it did still look more like a pbook. I also double-sided taped business card windows from a planner into the front cover to hold memory cards and the like. Since then, I found some self-adhesive pockets made for 3.5" diskettes on clearance at Office Depot for about $1 for a pack of 5. These also work well for card storage.
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