Here are the steps I used to actually create the blu-rays:
1. Acquire a film in .mkv format
2. Use MKVExtract 2.2.2.9 to split this file into its video, audio, and subtitle tracks (~30 seconds)
3. Use tsMuxer 2.6.12 to repack these tracks into a Blu-Ray .iso (~30 seconds)
4. Burn the .iso to a blu-ray disc (~10 minutes)
The result of this raw process is that there are no fancy menus or anything, which I felt would sort of spoil the experience. You put the blu-ray in the player and it begins the film immediately. But there is also no compression or re-encoding involved, so zero loss in quality.
For those just above me who are asking about commissioning someone to assemble a box set for them -- I DO have the extra materials lying around to make three more box sets. But I am also extremely wary of having a new asshole ripped open by 20th Century Fox / Disney to the tune of hundreds of thousands of dollars for selling copyrighted merchandise. So, ah, PM me and we can work something out, maybe.
I've PMed Spheretronic asking for the source files for his covers and the box set -- with his permission, of course, I'd like to do a little personal tweaking of the text (kerning and brightness and so on).