Ok, seems to work much better I've updated the generator to fit your provided measurements. In addition I have tried to fix printing multiple pages but I'm not entirely sure that the margins are generated correctly. I have switched to setting the margins using a CSS @page rule which means that in Chrome margins now simply have to be set to "default" and in firefox this method should also work. However, the generated PDFs seem a little off and I can't do a test print at this moment. Testing and bug reports of this version are very welcome: https://github.com/jonls/openpaperwallet/tree/update-template

Thanks for the offsets! Something seems to be wrong here though, when compared to your templates. E.g A is placed almost as far into the note as it is wide. Should I subtract the margin (0.5in) from these numbers?

I mean the top left corner of each element relative to the note but the size of the margins would also be useful.

acorn, is it possible for you to provide measurements (in mm or inches) for your templates so I can update the code that generates the overlay to fit perfectly to the new suggestions? I would need to know the width and height of the boxes (A, B, C, ..) and also the offset of the top left corner relative to the top left corner of the note.

Thanks, I can reply now. The code is also available in this fork https://github.com/jonls/openpaperwallet . There are still some bugs to be sorted out but I hope this provides a good foundation. The layout is done using a style sheet that only applies when printing, therefore it will look more or less like bitaddress.org on the screen. However, when printing the layout changes to comply with whatever scheme that is decided upon (currently it is set up to the scheme proposed by acorn). When printing it is important that the browser does not add any margins to the printed page otherwise it won't fit correctly to the scheme. This can for example be accomplished in Chrome by setting "margins" to "none" in the print dialog.

I sent a pull request for a patch to the bitcoin-qt client which is apparently being discussed here: https://bitcointalk.org/index.php?topic=154682.0 . I'd like to be able to join the discussion.