I created the layout in two parts in Adobe InDesign:

and

I sent the images via email to Beaver Engraving, and they created magnesium dies:
and

Sarah had decided on green and brown, but I selected the actual shades with the help of my Pantone Color Formula guide:

I started with the green which was 35 parts yellow, 1/4 part blue and 1 part black. I didn't use a scale but just approximated the amounts, and quickly discovered that both blue and black go a long way fast. I ended up having to add a little more yellow because it had gotten darker than I wanted.

One thing I hadn't anticipated was all the fooling around I would have to do with the makeready. Because I had never printed anything of this size before on my Pilot (the finished card will be A6), I did not realize that the printing surface was so uneven - the bottom half printed perfectly while upper half barely made an impression. I spent a frustrating hour building up parts of the makeready with small strips of strategically placed pieces of paper only to take them down again after a practice run revealed the build up affected the immediately adjacent area.
The final results of Part I were pretty but a few were slightly uneven:


