The calibration didn't align the front and back 100%. I used Zoom: 3, Shift: 7 if that helps anybody else.
With any combination of zoom/shift settings, did you manage to get the calibration page to print out perfectly *centered* (horizontally centered, that is?) That's the factor that influences how accurately the front/back line up. For zoom 3 / shift 7, what browser / OS were you using?
If anyone reading this thread is scratching their heads, this is what we're talking about:

So far I've had the best success with Safari, pretty good with Firefox & IE, possibly some problems with Chrome.
Any chance there will be an option to specify the size? Would that mess up the Zoom/Shift settings? I think it would be cool to have it the same size as paper currency, but I suppose paper currency has different sizes throughout the world.
Not yet. I'll think about that some, like a "master zoom" function. However the resulting wallets wouldn't size properly for the tamper-evident tape I sourced -- so you'd be obligated to use regular tape.