Like Roman mentioned, I print my custom decks directly onto 110 lb. cardstock. I print card backs directly onto the reverse side of the cardstock, and I too have very minor alignment issues with my printer at home, but they are so miniscule to not really be noticeable without a microscope. After dozens of trial and error printings, I've got my settings worked out to near perfection.

But, my goal is to go through and revise all my custom decks, and then take them to a place like Kinkos and have them printed on glossy card stock so they look as close to the originals as possible. I'm just not willing to work over the cash for that until I'm 100% satisfied with all my custom decks. Until then, I'm happy to simply print on cardstock.

As for maps, they would fit on 11 x 17 paper, so if weren't satisfied with printing/taping with your home printer, I'm sure Kinkos or something similar would be able to print the maps onto 11x17 cardstock.

One idea is to print on two sheets of sticker paper, and rather than stick to extra maps you're not using, try to get ahold of some other cardboard (not the corrugated kind used for moving/shipping boxes) and stick them to that. Something like a cereal box or shoe box or something would be about the right thickness after you stick the paper on it.

Darth Trumpetus...trumpeter of fury.