Step 1: Assemble Your Supplies
1) Your card designs
2) Cheap pack of playing cards
3) Mailing labels
The playing cards can be picked up at the dollar store (2 packs for $1 at my local Dollar Tree) as can be the mailing labels. That means you can create 112 unique cards (these decks have 4 jokers) for $2 in supplies.
Step 2: Printing the Cards
The first is to use Excel or a similar spreadsheet as shown in the template below. This enabled me to print vertically on the labels (side ways) matching the orientation of the card.
The second is to use a word processor, but you may find it hard to do vertical labels.
The last choice is to simply write on the labels by hand. This gives you the greatest degree of flexibility but the most work as well.
NOTE: You could also use the nanDeck program mentioned in my other instructable which would make the vertical printing much easier.
Step 3: Finish the Cards
The good news is that the cards shuffle and handle well.
The good/bad news is that the labels can not be removed which means that the deck will last but you can't easily change the cards. Your only real option is to stick a new label on top.
Which brings us to the bad news. The labels had a little thickness. You don't notice this with a few cards, but when you have a lot of cards you will notice it. This get's worse of course with labels on top of labels.