The actual card design I have to thank Sotoris for. He who runs our PBF game. I knew they'd be the ones I used from the first moment I seen them. Everything about them is how they should be. I've created a combined PDF if anyone's interested, nicely organised in the document.
For the character sheet, I might scan a neater drawing rather than design it in Photoshop, probably be easier.
As an aside, it's awesome that your group is excited for regularly scheduled sessions!
It comes and goes in phases, I'm hoping we keep HQ on the table for a while.
Thanks for the input everyone, it's really appreciated.