I like the concept of this post, and I agree that more people should figure out shipping before they start a Kickstarter project. However I disagree with the way you're calculating time and money on this. You've also over-inflated your numbers by using gross revenue instead of net profit.
Federal 52 Raised = $149,156.00 during it's 40 day campaign period
Backerkit Period = $15,728.00 during a two week post ordering period
Total Capital Raised in a 54 day period = $164,884
I worked an estimated 200+hours during that time period doing: Design, Answering Backers, Kissing Babies and Shaking Hands, making sure my wife didn't kill me.
$164,884 / 200hrs = $824.00 per hour
(obviously this number is different with EVERY project but the equation is the same)
Hour spent fulfilling packages = 140+ (2970 orders)
During the fulfillment time I was making $0 and could have been preparing for my next project.
Money lost while fulfilling = $115,360
That above number makes it a NO Brainer for me to pay a fulfillment house, even if they charge me double, it is absolutely worth my time.
How to estimate shipping cost
Shipping for your project will roughly come out to %16 - %18 of your total pledge raised.
I raised $164,884 for the Federal 52 Part I project and spent $27,000 on postage and fulfillment.
These are all estimates, I don't know the exact numbers you actually paid
Kickstarter Revenue = $149,156.00
Kickstarter Fees (5%) = -$7,457.80
Amazon Fees (3%) = -$4,474.68
Backerkit Setup Fee ($299 + 1% of Kickstarter Revenue) = -$1790.56
Backerkit Revenue = $15,728.00
Backerkit Transaction Fees (3%) = -$471.84
USPCC Setup Fees ($710+ per deck design) = -$1,420.00
USPCC Printing Costs (~$3 per deck x 14,899) = -$44,697.00
USPCC Uncut Sheets ($10? x 450) =-$4,500.00
USPCC Shipping (No idea, and I may have overestimated the sheets, so I'll skip this one)
Postage and Fulfillment =-$27,000
Net Profit ~$73,072.12 (minus the production costs of non-card rewards)
Hours Worked = 340
Hourly Wage = $214.92 (↑)
You were paid to
Design, Produce, and Ship the decks. The fact that the production and shipping occurred after you received payment doesn't mean it's time you weren't paid for. That's the attitude of every project that has failed to deliver.
In calculating the cost of using a fulfillment house, you need to look at how much they will take from your Net Profit, the difference that they get on shipping rates/supplies and if it's worth paying someone else to handle it. Let's say the fulfillment house charges you $8,000 for 3000 orders (you will still have to pay them for postage and supplies). Your hourly wage will go up, but your net profit goes down. At those numbers ($8,000 / 140 hours) you are now paying the fulfillment house $57.14/hr. If you can produce a design every other month, the fulfillment house is a great idea. But for most designers that are doing one deck a year at $12,000, they might be better off shipping it themselves.