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Does anybody know the safe printing area of a typical space marine shoulderpad and/or lower leg segment? I'm at work at the moment and can't measure any of the minis, but I can fire up Illustrator when nobody's looking.

The Bolter and Chainsword forums have a template that has all the sizes set for you.

When I made my custom decals (a unit insignia that went on a marine kneepad - very small!), I just experimented with microsoft word, and put the font down to different sizes, and printed it out on regular paper. Then I cut out the decal and saw how it "fit". Once I got a good size, I just printed it out on decal paper.