I've actually had pretty good success making customs using PowerPoint. I use a pretty basic design (full bleed picture, logo in the corner, rounded box on the bottom for the sig) and it's easy to do.
Regular size. You can fit six easily on a regular-sized sheet. I use the thickest card stock I can find that my printer will take, and I use a regular matte finish, not a glossy finish. I tried glossy paper, but it didn't print correctly and was hard to sign.
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