Not a bad idea. I don't have any idea what printing 1000 boards might cost, but I produce individual boards and sets for somewhere around $5 or so each. I print two half-boards based on the "Deluxe Camelot Board" download from BoardGameGeek on 8-1/2 by 14 paper. Color copies of these cost about $1 each. I then join the two halves and get the board laminated for about $3; this produces an indestructible, attractive board, but not a foldable one. I'll post a pdf file with the half-board I use shortly (it's on another computer).
If you want a folding board, blank 4-fold boards are available for $4 each here:
or instructions for DIY are here: http://degroof.home.mindspring.com/boardgame/boardgame.html .
The cheapest source of pawns I've found is this eBay dealer:
who sells a set of 48 pawns in four colors for $2.40 including shipping; this is enough for two full sets of Camelot men. For knights, replacement Sorry pawns from Hasbro.com work well. A set of 16 of these in 4 colors costs $3 including shipping, giving you knights for two complete sets. So you have two complete sets of pieces, with a few spare men, for $5.40.
Likely bulk ordering can reduce these costs somewhat, but I find these serve well to introduce newcomers to the game.
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