I will make sure to add some information about the open source software I used to create "Everything You've Heard About Love" to my site very soon. Meanwhile, I'll quickly answer your questions:
1. Copyshop & CD-R, or 'offset & glass-master'. I've never worked in a duplication house, but I'm assuming they use the latter (They're the pressed kind of CD in shrinkwrap, not burned). I've also burned them myself with print shop covers (the first 100 were custom made with a special poster insert that would have been too expensive to have done in such a small run at a duplication house.). So, I guess, both. The only difference has been the layout files, for the duplicated cds I had to send postscript artwork, and at the copy shop I send PNG. One thing I've got to mention is that I LOVE your idea of open sourcing all these files!. When I was making this album I was very new to graphic design, and as such was in the bad habit of saving all my .xcf files for the gimp only after I had used the "flatten image" option, exporting to png, and then importing into scribus. I also never saved any scribus files. I would simply export the needed format and save that file for future use. I've since changed my working habits and hope to make my entire next album available in the original open source files for non-commercial use. It's ideas like yours that really enable newcomers to make sense of open source!
2. Did you use proprietary audio plugins? No. In fact, although I use an amp-simulator with built-in effects on guitars in a live settings. I used CAPS amp simulators and various LADSPA effecs as replacements on this album. All you hear is open-source ;-)
3. What format did you use as a production audio master? After the mixes were complete, I added each songs two track wav to a master Ardour project, on separate tracks. The master channel of this project had relatively static mastering tools like a JAMin insert, limiting, eq, compression and tube-warmth. By keeping each song mix on its own track, I had lots of fine control over how each song balance with one another, and was able to do smooth transitions between songs and some sound effects as fillers. This whole section was exported to a wav/toc file pair, which I burned with cd with k3b. That burned CD was the master for the duplication house.
4. Font licenses? I used FreeChancery Italic and DejaVu (both sans and serif). All are Free fonts.
Nonetheless, as you mentioned, you couldn't find any of this info about "Everything You've Heard About Love" anywhere on the web, so as far as you could see, you were the first! First "First entirely Free album" post, anyway ;-)
BTW, I love your tunes.
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