Thank you, Tanakit, for your good suggestions. I wonder if I should make the single (step 1) word cards always the same font size (about 3 inches total height) and in red, regardless of whether it's to be used right away or when we are already on the 3rd, 4th, or 5th steps with the boys (because you are still teaching new words when you are up to any one of the steps, right?) I just figure that then, if I am progressing slower through the steps and starting at a younger age with the little miracle in my belly, then I can still use any of the single word cards that I've made. Does this make sense? Would it bother a 3 or 4 year old, who is used to reading much smaller and black letters, to still be getting all his new words giant and red?
I tried the suggested 6" x 22" posterboard word cards a couple of years ago (life happens and our dive into Doman was a very short-lived one) and I found that size incredibly cumbersome. But I am thinking of following someone's suggestion to me of sticking with posterboard. I have a laminator and could laminate all my word cards, (even baby #7 might not be the last baby we'll use these on

) but still the cost is much much higher, and the laminator will only take 8-1/2"x11"... at 2 cards per sheet cut lengthwise that's $.36 per word card... posterboard cut 6"x22" would be $.16 per word card, and posterboard cut 5-1/2"x14" (8 to a board) would be $.08 per word card. So that's quite a difference. I am thinking of doing the 5-1/2"x14"... it'll be less cumbersome and more affordable. Does anyone think that won't be big enough? Maybe for Step 3 phrases and Step 4 sentences I could do 2 lines lengthwise on 8-1/2"x11" cardstock... is it terribly important that the phrases and sentences be on one line only?
Well, time and money are precious and I only want to do this once and make materials that will be good for whatever age I start with, so I seek good advice before I get started.