We finally finished our boarding pass STDs last night and I love the way they came out! First I want to thank everyone on this forum for sharing theirs, it was a big help in putting mine together! Here they are:
I used Aylee Bits :: Aylee on weddings, design, personal finance, travel, photography, the internet and more for the boarding pass template and used Microsoft Publisher to do all of the editing. I printed the STDs on white 65 lb cardstock with our home printer and they came out better than I expected! For the covers I used Wausau 65 lb cardstock in Celestial Blue and the envelopes were Harvest Orange in case anyone wants to know the colors. I used a rotary cutter to make all of the straight cuts and ended up cutting the round edges by hand because I bought the wrong paper punch! It ended up not being too bad.
We also printed out our address labels. I was excited because I got to put our logo on our return address labels! Luckily a friend had packs of the Avery printable labels so we just stole one sheet of each since we didn't need a whole pack.
Overall, I believe the invitations cost about $0.65 each in paper (including envelopes). We bought new ink right before this project and only used about 1/3 of it to print 25, so I think we did pretty well with the final price. Hope this information helps!