Best way to position fields for filling printed forms

[ac110]

I'm volunteering for a charity which, one day a year, takes a large group of children to Disney World for a day. We have Canadian and American customs declaration cards to fill out, the ones you always get on the plane flying into the country.

I have about 250 people, with one CBSA and one TSA form to fill out for each.

Preparing for a mail-merge, many hours of positing form fields with the {ADVANCE} field seems to have me most of the way to one of the forms, but I can't help feeling that there must be a faster and better way.

I thought I'd just calculate at 72 points per inch and use a ruler to determine positions, but that seems to be a mixed success, the positioning isn't perfect. I'm contemplating scanning the form and inserting it as a page background to see if that helps.



How do other people deal with this task? I'm certainly not the first person to deal with this.

If I should be looking at different software altogether, I'd consider that.