Doctor President is my new hero
She's pretty awesome, ain't she?
I think it's a great idea. However, I also believe that the "feel of the bits" in a board game are important, and looking at Erin's play-testing photos with curling squares of paper made me cringe a bit.
So, it would be great to figure out how to get beyond the "PDF and print it yourself" model. Maybe with limited run prints on real cardboard or something? I suppose that hardcore, crafty fans will glue the PDF bits to cardboard backing on their own... but most people will not. And... ahem... the PDF of Treehouse does not include rules? Where are the rules?
Time to put on my German Board Game Evangelist hat for a sec. I'm assuming that anyone considering doing this has played tons of great German Board games already (from the look of Erin's game, it seems like she's in that camp). If you haven't, it's time to get googling, lest you unleash another sub-Ameritrash racetrack game on the world!
Here's a good place to start:
http://scv.bu.edu/~aarondf/Top100/Good to play these even if you don't plan on making a board game, because they can help you think about games in general in new ways.
I used printer paper for the sake of convenience, but you're right that it made the game a little precarious. Laughing on the game board was catastrophic and strictly prohibited. It certainly would have helped if the tiles had a bit more weight. If you look closely, you can see that I taped pennies to the bottom of the player pieces. Incidentally, I borrowed those pennies from Zaknafein's desk.
I'll have to check out those German games, they look pretty interesting. Thanks for passing along the link!
And by the way, due to popular demand, I've edited my blog post to include the game rules.

They were sort of covered in the link in the first paragraph, but now they're all in one place.
TheIvy: I bet each game was preceded by a fight over who gets to be Doctor President.
I remember I used to make board games when I was a kid. I think I spent most of my time getting together stuff to use as tokens. Paper squares were not acceptable to little six-year-old me. I'm sure if I looked in my parents' attic I'd still be able to find big pieces of plywood with green felt glued to it and weird mazes and monsters scribbled all over.
I always try to play as Freckle, but maybe I'm biased.
I used to make board games when I was a kid, too. The most ambitious one was a Calvin and Hobbes-themed racetrack game. The most dangerous one, I built on a pane of window glass I found in my grandma's attic.