The GM at saturday's event had all the cards in protective card sleeves. With the myriad of sizes for card covers out there, does anyone know the dimensions of all the cards in the set ?

You need 167 green standard american sleeves and 224 yellow mini american sleeves.

Wow...precise to the card count! Thanks! Don't suppose you have that info for the expansion toolkit?

Per the toolkit description:

" The Adventurer’s Toolkit is also perfect for new players in your campaign. Inside you will find more than 50 action cards, 30 talent cards, 10 new careers, 4 new party sheets, a pad of character sheets, new character standups, extra tokens to help manage your heroes, and much more! "

So, you'll need more than 50 more standard american sleeves (1 more pack should do since you'll have extras from the 4 packs required to sleeve the main game) and also 30 mini american sleeves.