If you have the full Office package, you can also do a Mail Merge into Word, which might have support for other sizes than 8 1/2 by 11 forms. If it is a standard size Avery form, Word probably will support it. Don't know if there is a standard Avery post-card form, but if there is, that might be a way to go.
If this is how you want to go, you could build your database. Then build a query that holds the specific data you wanted to print. Save the query.
Now open Word. From the menu bar, you can use the Tools >> Envelopes and Labels >> (Labels tab) >> Options to get to the dialog box that lets you select the pre-defined form you need.
Select that form. The display should change to match the size of the new form.
Now use Tools >> Mail Merge to create the form.
This doesn't answer all your problems, but it might make at least some of your mailout process easier once you get it set up.
