Vistaprint is great, but although they are free,the postage charde is tiny if your prepared to wait up to 2 3 weeks for them to be deliverd, if you want quicker it can cost up to £10 depending on what you order, but the quality is brill and well worth it
but saying that i have just created my own on microsoft publisher and bought business cards from staples £8.99 for 150 cards i think, and it shows you what to set printer margins too etc, and i tried last night, they printed brilliantly and i am very impressed tbh, cos i can just do as many as i need at a time, last time o ordered the 250 free ones from vistaprint, and ive now changed my service menu and website, they are all useless and so ive done myself soem new ones im chuffed lol
see small things amuse small minds lol
hope you get it sorted chick xx