Hello -
This is what I've been able to use to come up with some great custom print projects. Granted this option may not be possible, for some of you, but done the line it might.
I was in the market for new printer, and purchased a Brother CLP-315. The first one was a lemon, but I gave it another chance and I am glad that I did. I purchased it at a local Office Max, for $150. The CLP-315 does excellent color laser print work on a visual level equal to that which Fantasy Flight produces. I needed to adjust the contrast, saturation, levels, ex cetera... and now I have my Arkham print setting.
When printing monsters, I purchase 120 grade white shiny paper. The paper will curl coming out of the CLP-315, as this stock is rather thick, but this is a non-issue once you start cutting and glueing. You can use 90 grade, with likely equal results.
Once, the monsters are printed up, I commence on the cutting. After cutting is completed, I then use Scotch glue sticks, $4.00 (flows nice, little to no gumming), and then paste onto thick tag(?) board that I can buy for $4.00 a sheet at Office Max. (This is enough board space for 100 monsters give or take.) Glue the monster to both sides and let stand. Don't stack monsters on top of each other, for glue overflow might stick several monsters together. The monster thickness is nearly equal to that of Fantasy Flight. When drawing out of a cup, unless your a braille reader you will not notice any difference.
At this point, and for the following cards, sheets, items ex cetera... you can spray a protective coating to prevent smearing. This protective spray can be picked up at nearly any art supply store for $5.00 or less. I don't use it, but it is an option. They spray will create a gloss effect. There might be matte sprays but I don't know.
When printing investigator sheets, scenarios, items, spells ... I always use 120 grade paper, although 90 or less will give you thinner cards. Then I either cut and glue the paper to thick white poster paper, that can be purchased for around $1.50 - $1.00. Another option that I use sometime is to recycle old (poker ) playing cards, or really any card that is the same size (or near) as the Mythos, Gate, and Locations. Pasting over old cards, yields thinner cards, and strong support spines. Again, you can spray a protective coating, which some of you might like, as the texture differences between printed cards, and Fantasy Flight's slippery surface is more noticeable. Again, I don't notice this until I am actually looking at the card.
I often have a large mixture of custom and official, and everything looks great, and better yet plays fine.