When the DVD came out, I decided I had to make a set. I used a computer to get some frame grabs of the cards, which were shown in extreme close up in the film. I then used Photoshop to straighten out the cards so that they were the proper aspect ratio. I then imported those images into Adobe Illustrator and painstakingly traced over each line on the card, and matched the fonts of each piece of text.
It was a pretty challenging venture, as many of the fonts were difficult to identify.
After drawing out the templates, I also traced the signatures that were shown on screen, so the cards are highly accurate. I also made them so that the names and cities on the cards could easily be modified, allowing me to make all manner of variation for my friends.
After the cards were done, I printed them out on my HP 970Cse, and had them laminated.
My initial run consisted of cards for "Jay", "Silent Bob", and "Pumpkin Escobar". The Bob card was not seen on screen, so I signed those myself. I initially left the signature line blank, but everyone thought that looked lame.