Okay, a short list of what went wrong: went to Kinkos when they were closed (I thought they were all open 24/7), Kinkos guy added too many cuts, other Kinkos guy cut cards so they weren't square, had the wrong envelopes, returned envelopes to paper store when they were closed, ran out of ink (several times) and several other minor disasters.
What made it totally worth it was getting this email from my customer, "I got the invitations yesterday!!!! They are awesome; you did a great job. Thanks for the extras and the fronts of the cards (from the mishap) - I will definitely put them all to use some way... we are all good!"
So very happy!