My boarding pass STDs are finished, so I thought I would post them for everyone to see! My fiancé and I recruited the best man and his girlfriend to help make them. Overall it took the four of us about 4 hours to cut, assemble and address them. We used a paper cutter, and a corner cutter for the majority of the cuts, but could also get away with just using scissors if we cut carefully. We got our STDs printed, as we didn't want to deal with printing them ourselves.
To make the STDs I used corel draw, as I use it at work and am familiar with it. I also tried it our in PowerPoint but wasn't as happy with the results.
If anyone wants instructions I can probably piece some together.