Sorry for the long delay to all that have asked for an update, family and parenting come before obsessive hobbies, right ?
So as promised I've tested various printing options based on many suggestions throughout the depths of the internet. I thought I was going to give up on the home inkjet approach, but I'm glad I didn't. The silver bullet for cost effective home inkjet cartridge labels is...
Labels: OL175WG
Laminate: Scotch Clear Packing Tape.
I printed two different tests, both with and without lamination. I'm leaning towards the laminated look for SNES cartridges and the non-laminated look for Genesis cartridges to match their retail look and feel. Both look incredible and do *NOT* show any signs of ink bleeding which was always the problem with all other printable labels I've tried.
Some pointers:
Clean your cartridges! If you are transforming (destroying) a cartridge into a different title you will want to make sure that the original label and glue are entirely removed. Also, you will want to clean up any grit or grime that may be lingering on these old cartridges. Opening the carts and socking the shells in anti-bacterial dish soap over night is a long but easy way to loosen up the label and its glue, plus remove any unwanted filth and contaminants that may be lingering. Use a thin putty knife to shave off the sticker and glue the following morning and the use some glue gone to remove any remaining traces of glue. Afterwards a final washing through the dish soap is a must to remove any traces of glue gone and perhaps a quick brushing with an old toothbrush.
Proper print settings are a must! Assuming you are using the same labels then you will want to make sure you're printer property settings match the paper type you are using. On my Canon MP610 I'm using the "Glossy Photo Paper" and Print Quality as "High" setting.
Lamination:
Measure twice, cut once! Align the sticker so that all sides will be covered by a single piece of tape. Go slow and pick one of the 4 sides to start with and then slowly slide your finger left and right while slow creeping forward to make sure the sticker applies without any bubbles.
I hope this helps others who have struggled with this topic as I have... Many people refuse to share this info because it will eat into their profits or any other personal hang up they may have, I believe in giving back. The Nintendoage community has been very good to me and my appetite for projects such as these. I appreciate the labels that others have created and have freely shared with the community. I plan to do the same to encourage others to share as well. If someone wants to make money off of someone elses work, then so be it... They're destroying the hobby for themselves in an increasingly saturated reproduction market. A hobby stops being a hobby the moment it becomes work!
Best of luck to everyone.
Some examples - Not laminated:


And Laminated:
