I am doing the Insanity Quilt by Rhonda Pearce - 10,360 half inch hexagons! I started buying the papers from Paper Pieces but that was running into a lot of money. Then my girlfriend suggested getting the Fiskars hexie punch and using the inserts that come in magazines - thicker than regular paper but not as thick as file folders. These have worked beautifully.
Then I found an AccuQuilt die that cuts the fabric with a quarter inch seam AND the perfect size paper hexies. I have been cutting 4 - 6 layers of fabric and 2 - 4 layers of paper at a time. I still have a long way to go but the ease and precision of the die is wonderful!