Kim, I know it may not be exactly what you wanted, but have you looked into www.mixonic.com? You upload your files to them, design your own cover or use their stuff, then order as many as your budget can handle, from one on up. They're not bad depending on the quality of your sound files, etc. and the staff are really great.

Sorry you've had other necessities for yer cash. Sending lots of good thoughts for whatever works out best for you and Mister.:-)

kat