HereForTheBeer: Have you tried a local print shop?
For my own needs I hit up a local shop to help with the logo and card layout, and then used them for printing the cards and one other document. The 500 cards, with logo design, was something like $30. I went to a few clipart sites, snagged some public domain elements, and merged them into a rough idea of what I wanted. Gave the basic files and my rough layout to the printer, told them what I wanted the finished product to look like, and it took them maybe 15 minutes to do the graphic work. After adding adding in my text, it was ready to go. Super simple, and cheap.
WRT business name... take a look at the business site of your state government to see what you have to do to get a name. To find where to go, I searched for "business name registration" [state] and it took me to the appropriate place. It was a one-time fee of $11 to get the name I wanted; hopefully it's that cheap for you, as well. For a sole proprietor, that's about all it takes to get a DBA going though you may also need to dink around with licenses and sales tax numbers, depending on your state's rules (check with all states involved if you're going to work across borders). In order to cash checks under the business name, I opened a biz savings account at my bank, directly linked to my personal accounts, basically as a placeholder so I can accept checks written to the business.
Thanks for the additional information. I will look into using a local print shop or an online shop for the final drafts. I am currently just trying to basically setup a prototype to work with, and possibly have a few on hand until I can make an order. I have avoided clip-art sites so far, due to the fact that sometimes some of the clip art isn't as free-to-use as they indicate, not that I would likely be caught anyway, especially with a small computer repair business.
As far as the other side of what you said, I do know that, atleast here, you have to register with the county clerk's office to get a DBA. I believe that is 15 or so dollars, then you have to run an add in the local paper for 3 weeks indicating you will be DBA whatever you company name is.
I have been working on some TOS and other documents to accompany my work, and to cover my butt, I just have to finish them and have an attorney look over them. Still stuck on the name I want to use, but I still have other stuff to finish before I can do that. Up until now, I have just be "that computer guy" that a group of clients of mine call to get their computers fixed, but it doesn't pull enough money, so I need better advertising, which means fliers, ads, business cards, and an actual company name.