I downloaded 102 of the characters and formatted them to be 4x6. It's a pdf file and only one per page (wasteful but didn't want to deal with formatting 2 per page). If anyone wants it, feel free to PM me. You can take it to Kinkos and they will cut and bind for you.
If you need to add any additional, go to Word, do 1/2 inch left margin, 1 1/2 inch right margin, insert picture, right click picture and format to 4x6. This will match the other pages perfectly.
Some characters plus the customized characters at 1900 Park Fare breakfast, Ohana breakfast, Akershus, Jedi Mickey, and Galatic Breakfast.