Physical letters do not obviate scams, nor is the cost that prohibitive. I remember actual 419 scams on blue airmail all-in-one letters back in the 80s. And that was international post too.
I have an inbox, and I do not receive a lot of scam post. In fact, I don't think I received any since I lived at this address (~10 years ). We do get a few promotional leaflets every other week.
OTOH, I get hundred of spam emails every day.
The former is something which I can handle manually easily, the other is not.
If you are targetting a list of well-known authors I guess outsourcing the writing of a couple of hundred handwritten letters shouldn't be too hard. I'm sure they they can find a school class in Nigeria or Kenya who would gladly do it for a few dollars — or a struggling teacher willing to get creative with the homework assignments.