Many people had the same idea, and so did I. I started out creating all the required graphic parts and layers in Photoshop, when I ran into ready and complete templates online. Turned out somebody had already done all the foot work (exactly what I had been setting out to do), and creating cards was all of a sudden a couple of weeks of painstaking graphics work closer!
I believe I found the templates (.PSD; for Photoshop) here:
http://community.fantasyflightgames.com/index.php?/topic/92400-new-custom-pilot-crew-cards/So I set to work witht he ideas I had, and these are the first results. I ran the cards by my trusty proof reader Voivod, and I changed some details at his suggestions already, but I feel there are some minute changes still required to make the wording clearer (I'm looking at you, Aeron Azzameen...):
















There's still some colour discrepancies when they're printed, but that's a local problem, which will require different settings on each and every different setup. Be prepared for some trial and error there, if you want them indistinguishable (which I of course want

). Oh; and invest in a corner punch with the correct radius to finish the whole thing off...