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Well, It seems to me you can either increase the size of the blank or slightly decrease the size of the pattern. Most printers will allow you to increase or decrease the size of you printing job.
Arborvitae is a form of cedar. I think it is called white cedar by some people. I have not used it to paint but know Cedar can be oily so yes I would recommend sealing.
Like millwab, I get mine from Cherry Tree/Wildwood which has both 1/8" and 1/4" poplar ply. I like the 1/4 for puzzles. You can contact them at www.CherryTreeToys.com or 1-8oo-848-4363
George
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