I also printed it on Lulu several years ago - worked great.
Just tried to do this, and found that the cover image size doesn't seem accurate anymore. What did you do for the cover?
Really? I just made the book and ordered it last night and the cover (the 13MB png) looked like it lined up exactly. The first cover-uploader had a 10MB limit but the other worked fine (not the design-your-own, the 1-piece-cover-designer).
Turns out I was trying to get a hardcover. It worked just fine with a paperback.
The link to the lulu's book is not working for me... Can you please share it?