Well, you have to understand that I do some design work on a professional basis (one of my other avocations is as a RPG and board game designer), so I have a lot of tools at my disposal. I use Adobe Illustrator to lay out most of the stuff, and Photoshop to clean up the decals. Actually, a lot of my decals are imported into Illustrator and re-drawn there - that was the case with the Cherokee D and Alpha. To get the pdf files small, though, I have to save the files as pdf files, open them with Acrobat (full version), save them as postscript files, and then open convert them back to pdf with Adobe Distiller. It is a lot of steps, but the pdf of the current version Alpha started out at about 300+ KB coming straight out of Illustrator, and by using Distiller, I got it down to 44 KB - worth the time and trouble.
Greg