If you use Fantasy Flight Sleeves they will not fit in the box.
i use perfert fit from Max Protection
I use Max protection sleeves and they fit in the box for the second printing of the enhanced edition (my friend has the first printing and they don't quite fit in there apparently) They take up more space in the box though- my EE box fits the core cards and then all the mini expansions, but by the time they're in there the box only just has enough room for my bag of tokens.
When I get the IR/RC and vengance boxes my intention is to try and have a box that holds all the cards my mother doesn't now (she currently only has the EE, unity, ambuscade and silver gulch) so when I go to visit her I can take the cards she doesn't have easily.
Since I'm getting a (rather large) fan expansion printed, I won't be able to fit everything (unsleeved) in even when I get the Vengeance box. I'm considering using some of my mad craft skillz to make my own smaller box just for the Cauldron - I usually don't even consider splitting up heroes or villains or environments, but since the Cauldron's unofficial I can reconcile myself to that.
Assuming that Printerstudio's cards are the same thickness as the official cards, the expansion would need just over half of an EE-sized box.
What type of card stock did you use, I love the Linen cards, but they are about 2/3 the thickness of the official cards. I have them sorted into the official cards and it is noticable.
I went for the standard smooth cards. Cheaper, and I thought they'd match the official ones better.
I do love linen texture though. This'll be my first look at the quality of PS stuff (first order from any POD service in fact) so I'm looking forward to seeing how they look. They should arrive at the end of next week.
How much did you order of it, I have the first 6 heroes and There are a few that are in regular rotation. My sister loves the Zombie Summoner and Vanish has become one of my favorite decks to play.
Let me know how the smooth looks and feels, I need to place another order once a few more decks get finalized.
Dammit, typed out a long response and Chrome crashed.
Short answer: first 7 heroes, first 3 villains, first 3 environments plus the joke Tall Grass. HP tracker cards x17. Fan promos. Some official promos that I only have crappy proxies of.
Next order will be the rest of the Cauldron stuff once it's finished, including the joke Musical Swordsman hero. Three errataed Doc Havoc cards that I forgot to change in my first order. Cauldron dividers. My versions of Spiff's search sheets (his aren't the right dimensions for large cards, so I laid out my own). Probably Machi Koro and a reskinned Love Letter.
What dimension would you prefer the Search Sheets be? They're only formatted the way they are now to make them fit four-to-a-page. If I could manage that while still making them work for some other purpose, I'd probably be up for that.
If I could fold them in half and have them be the size of a card, they'd be perfect. Right now, they're so close to that, but I have to trim just to the text and it still doesn't quite fit.
That's my suggestion, anyway. 
Anyone else?
Thanks for asking, Spiff!
You're saying you wish each sheet was the size of an individual card? That would make them easy to slip into the deckbox they go with, but for some of the sheets there's no way I could smoosh all that text all down to 2-1/2 x 3-1/2 inches. You wouldn't be able to read it!
No, totally agree! I want to be able to fold them in half to make them the size of a card. 
That doesn't sound hard. I'll see what I can do.
Oh and my AZ and Scholar sheets are on standard cards since there's not much text.
My versions were formatted to fit the large cards that Printerstudio offers which are twice the size of standard poker cards - 3.5"x5.75" (89mm x 146mm). I had some space in my large card order so I figured why not slot the search sheets in there?
Mine don't have fancy graphics though since I lack Photoshop-fu. And Unity in particular was somewhat difficult to fit all the text in that area while including the necessary bleed at the edges. Hopefully they're clear enough. I've attached Fixer's card as an example, if you want to have a look.
If I'd just printed at home I'd have been fine with your sheets Spiff. I like them a lot, such a good idea.
Well, here's a sample storage solution for sleeved cards that is less fancy, but seems to be working for me. Attached some pictures as well.
Base Storage box is a plastic Sterilite file folder box. I picked up the pictured one in a Target store for $10. Sufficient depth and width (barely) as will be shown, and the lid has some storage as well.
(See Attachment 1)
The bottom of the storage box fits the Rook City/Infernal Relics expansion box. The RC/IR is wide enough to fit cards sleeved with Dragonshields - the EE box is not. Therefore, the RC/IR box holds all the villain decks and all the environment decks but four.
(See Attachment 2)
On top of the RC/IR box go two layers of smaller boxes - 12 boxes per layer. These are empty Dragonshield boxes being repurposed for each holding a hero deck. Plus one box holding four environment decks. There is enough room on the top left for a small notebook to lie flat as well.
There is also a large manila envelope that slips down one edge of the box. In this are the rules pamphlets from EE, RC/IR, and Vengeance. Plus the over-sized villain cards and the hero divider cards. I use the last with new players as a way to introduce the various heroes to them.
(See Attachment 3)
Last of all, the clear plastic flip-top storage on the box is used to hold status, markers, HP tokens, and a few miscellaneous items like extra dividers.
(See Attachment 4)
That's really neat, Silverleaf! You should post them. Not that I think either of the options are better or worse, but giving folks a choice is always a good idea, in my book. 
I don't know if I've ever said this, but the Search Sheets wasn't my original idea. There was a person on BGG who posted the first ones. I loved the idea so I copied it and added a little Photoshop-fu to it, but when I went to find the name of the guy who'd posted the original version, I couldn't find it to give him credit. Whoever you are, you magnificent person, I thank you.
What do we think of the this Search Sheet? Each one is the size of two playing cards (vertically, not horizontally). If we think this is the way to go, I'll update the rest of them. Rabit's right, they're almost that size anyway, so it's not a ton of work.
The EE box I use for my heroes is from the newest printing, so it's probably the same size as the RC/IR box. As soon as I get my 1st copy of Rook City back from a friend I'll be selling a full box of all sets before Vengeance for $50, which is half price, I'll be asking around at my game club first. They are my old sets and have gotten quite a bit of use and the edges are getting worn down (mostly just the Heroes), it's the main reason I'm sleeving my new sets.