new cards.

[thanatos]

I think the most cost-effective solution really would be to buy card protectors. The protectors are usually pretty darn cheap, and I haven't noticed any of my Magic decks slipping apart while I play, despite starting with a stack of 60. This would also allow printing on normal paper if card stock wasn't readily available, since the deck protector would keep the paper from taking too much wear and tear, although card stock would still be preferable when shuffling (a workaround would be to slide a playing card or other type of card in behind the printout to give the deck a little more sturdiness).

In fact, once I try one of these scenarios with custom cards, I think I'm going to do just that...I've got tons of deck protectors just laying around unused.