I love doing D-VHS covers, but all that work may be for just another year...when BluRay or HD-DVD replaces my D-VHS collection.
Re: paper, I've started using medium weight/matte finish photo paper. It's cheaper than real glossy paper & more importantly wastes less ink. The quality is close to glossy, but not quite as good.
Re: cases, I bought my D-VHS cases here
. They're a tad bigger than the cases D-Theater tapes come in.
I'll send Matt my D-VHS covers as well--the ones he doesn't already have.