I figure 6 disc set wouldnt be a problem because they could use 3 dual disc cases that are the same size as regular single disc cases, ive even seen dual disc slim cases so box size wouldnt be an issue (could use the slim cases and throw in a bonus disc or two and the whole set could still be the size of 2 regular size cases.
but another possiblity would be to use dual sided discs, but then you dont get a pretty picture on the disc plus i never know which side needs to be up to get which version (mainly discs that have full/widescreens on the dual sided disc, i swear they arent consistent in this regard).
Id buy something along this lines in a heart beat, it could be like the super collectors edition and have a case in the shape of a Death Star or something, that be amazing.
-Darth Simon