Thanks for the tip about the mini euro size for the smaller cards. Normally I wouldn't care but snagged a ROTWL set recently with the cards already cut out, so there we go...
I used color printed paper, plus a slip of plain cardstock inside a sleeve for the longest time. These were the "proofs" and I played with them quite a bit, before I finally ordered professionally done cards to replace them. Still, having them in sleeves is nice, and while I prefer the ultra pro "matte on one side, clear on the other" I just can't find any like that in a form fitting size. My MPC cards are slightly shorter on top than the classic originals, so putting them all in the same size sleeve covers that up and makes them easier to shuffle (sideways of course!).
As for the "worn" look, I actually print my new custom cards with fake yellowing and sometimes other little imperfections, so even though they have a nice coating (MPC "superior smooth"), they can "pass," at least at a glance.
This thread was also very helpful.
