That's easier said than done. You'd have to have some really impressive skills to make DVD labels (disc labels, box art, etc) that look like something that could be mistaken for an actual, retail DVD. On top of that, buying the printable labels, boxes, blank discs, the tons of ink you'll need, and so on can really be a drain on the wallet. Especially if you aren't employed. And the final insult to injury is having to resize a video, as in add black bars, to make sure the subtitles are readable on the screen. It's almost unavoidable since 9 times out of 10, fansub groups use HARDSUBS. I don't know what it is about doing that, but most of the time, you all ready lose some video quality when it's a hard sub, and don't get me started on using TV rips as the raw source.
I speak from experience. I've been wanting to do the same thing, and I've made lots of art for labels. So far, I've printed off nothing. And I'm the kind of guy that wants to go the extra mile and make English/Romanized logos that match the Japanese logos, just so it will be there in the DVD menus. I've reached a point where I support softsub teams. I want to be able to turn the subs off and enjoy perfect video quality. So far, the only subtitle group that gives us both of those is Over-Time. Other groups aren't bad, but they clearly know what they are doing at Over-Time.
I wish you luck, Glamador. I understand the novelty of wanting a physical copy you can have and play at any given moment. Maybe one day, there will be a collaborative fan effort for people like us. At least until that rare, perhaps impossible day when tokusatsu is given a translated and uncut release in our native countries.