So the boarding passes were made out of 110 lb paper from Wal-Mart, the envelopes were from 65 ib paper from Michael's. The beach mailing envelope was from Office Max. The magnets were made out of left over paper and the sheets of magnets with the peel away back. We bought and used a perforator, straight edge, and the corner cutters from Michael's. I will say the entire thing cost 61 cents to mail per STD. Each STD cost about $1.50 give or take a few cents. So with that said here are the pics. I will attach the templates for the STD and the magnets with the background. Let me know if you need any help or have any questions.
This is the entire STD, 4 passes.
The STD and magnets
The inside of our jacket
The front of our STD
Our beach mailing envelope