To Keith Carter(Bounder),
Could you tell me the measurements/scale you used to reduce the "OGRE Classic Counters" from the ODE to Pocket Edition, please? I plan on ordering blank counters from printandplaygames.com. Thank you for your time.
The ODE Classic Counters are 1" and the OPE counters are 15/32" so they are 47% of the size of the ODE Classic Counters. If you are aiming at specific counter size then that will probably change the print percentage since your trying to match the counters.
I did not use die-cut counters. I printed at 50% on letter sized sticker sheets applying that to letter size .06" (about 1.5mm) chipboard. I then cut the counters out with a metal ruler and a sharp craft knife (changing blades often) cutting just inside the magenta border around each counter. I ended up with counters just a hair larger than the OPE counters. The biggest problem I had was that it took multiple cuts to cut all the way through the chipboard and I had to make sure the blade stayed perpendicular to the surface of the counter to avoid counters with skewed edges. I had to be a little careful to make sure the fronts and backs of the counters lined up (registration). If you decide to go the sheet of stickers direction I can tell you how to limit registration issues.