Hey, Haz, were you planning to release a deck soon?
The most important thing any potential KS project creator needs, before even starting the project, is knowing as close as is humanly possible what every little thing is going to cost. Paul knows this - he's written of his spreadsheet prowess before. I did it in my consulting work for clients looking to launch on Kickstarter, in terms of knowing what not just the item being created will cost - the deck - but all those wonderful little rewards as well. Once you know what it will cost, you can deduce from there where to place it in terms of reward tiers.
Yes, KS gets a cut.
Yes, Amazon gets a cut.
Yes, the Internal Revenue Service gets a cut, at least in the US. When they get wind of it, so do the states and municipalities that charge income tax as well.
Your flat dollar figures of $17,000-20,000 leave out an important detail or two - namely, who's going to print your deck and how many are you making. It's entirely feasible to make a deck with a modest quantity of 2,500 with USPC and have a goal under $10,000. Tax-wise, you're probably better off that way. And as some people are starting to learn, there are other printers in this great, big world of ours that make decks at least as good as, if not better than, USPC without charging as much as USPC does. Keep your eyes open for Lawrence Sullivan's Legends decks when CARC starts selling them next month - they're NOT made in Erlanger, KY, USA!
You will NOT get clobbered on domestic shipping, if you properly factor in shipping costs when you make that spreadsheet I mentioned above. You simply have to know what things cost to ship, right down to the last reward. And yes, it costs more to ship out of the country - I have yet to find a country where this isn't the case. If it's out there, I certainly don't live in it, I can tell you that... The toughest part about managing international shipments is that, unlike domestic shipping, every single blasted package has to have a Customs Declaration Form to go with it, individually addressed and with all the contents listed. Pain in the tuchass.
What makes buying any KS deck through the project more appealing than waiting for the aftermarket is 1) you usually get KS decks at below the retail price and 2) without your support at the KS-project level, there will be no deck, so no aftermarket!
On the topic of the "early bird" offers, people have gotten wise and created projects where the early bird offers are limited to a single deck. In some cases, people got the early bird at insanely low prices and ordered huge amounts - that's where some costs can hurt you, depending on how attractively you price the early bird. So these days, it's structured more for people who want to get a deck but otherwise wouldn't be able to afford it and are willing to leap in there quickly at the start of your project to give it a healthy boost in the early stages to attract attention.
Pick and choose your extras wisely. While some projects had just the right selection, some started to look more and more like a flea market rather than a deck project! I'm waiting to see branded blenders, boy shorts and condoms to come out for someone's deck eventually... Not every deck needs poker chips - honestly, how many sets of poker chips does a single person need? A dealer button, perhaps, but a full (and usually expensive) set? T-shirts, yes. Art prints, perhaps. Uncut sheets are practically a must, though if you ask me, sooner or later you're going to run out of room for all that stuff on your walls! And if you call it an "art print", make it a REAL art print, and not something you cranked out on the inkjet printer on office paper and folded up to stuff in with the decks! Art books, though usually very limited, are popular, especially if it's for a company that's in the business of making decks, but the art better justify it or save yourself the trouble.
I'll leave the more experienced out there to talk from experience - my experience is limited to just the consulting I've done for others, having never done a deck project of my own. There's more I could discuss, but I do get paid for this kind of stuff, y'know...