Still no joy ordering copies from KDP for delivery to Australia, but after seeing a recent comment about Lulu on a different site, I decided to go and price them up.
I was impressed that you can enter various details and get a per-book price (and a delivery cost) without signing in or giving your firstborn as a sacrifice. This included delivery to Australia.
I was very impressed with the printing price and delivery fee. (Postage, the books being printed locally in Australia, is very good.)
So, I dusted off my login from somewhere around 2003 or so, and signed in properly.
They don't offer the paperback size I use on KDP (5.25 x 8), but 5.5x8.5 is close enough to use my existing interior file.
For the cover, I fired up Indesign, downloaded the relevant Lulu template and resized my existing cover in under 10 mins. Saved to PDF, uploaded, done.
I was going to order three copies, which worked out about AU$8 each including postage (274 page novel), but I've decided to upload a couple more titles and get a mixed batch of books.