Wayne--
I've changed PCs since creating ours; I'll have to see if I can find the originals on the old one, or at work.
However, if memory serves, the font sizes are 9 & 11 point(as opposed to a more "normal" 10 & 12 point type), with 7 or 8 being used for the "fine print", such as date of last update, or notes about dose & frequency of daily meds, with bold & italics used for emphasis when needed.
Re: The "tear here" notch--not a bad idea, but depending on what you use to laminate the card, it may be well nigh unto impossible to tear with bare hands (and/or teeth).
Thanks, too, for your kind words. Hope everything goes well with your little one "on the way."
David