Been studying The art of card splitting for a couple days and I just can't figure this out. Yes, I know that when you split a card it obviously becomes thin due to ya know it being split. However, When I attempt to take to faces or two backs and put them together they just feel really flimsy and thin after they've been pressed. Am I missing something or is this something I must get used to?

When you split a card there will be 'thicker' and 'thinner' halves. The thicker half is the one that also contains the glue originally applied to hold the two halves together. When you get experience with splitting you can determine which side of the card will be the thicker one, i.e. you can make the back of the card the thick or thin half depending on how you split it.

If you join two thin halves then it will be extremely thin and flimsy. In my experience, to best approximate the correct thickness of a playing card, attach a thin half to a thick half. That has always given me the best results. Two thick halves are a little too thick and unyielding. Best of luck.

Ok that's what I was missing! switching which side you split on each card, Thanks! Another thing, when I make my halfers there seems to be a weak point in the middle of the card where the two meet, anyway to fix that?

I have found that even splitting cards properly and re-gluing with rubber cement leaves a lack of snap. I've heard good things about using dry mount tissue/paper, but have yet to try it, myself.

That may also be because you are using the two thin layers. Cards are made of 3 layers. When you split, you are typically splitting 1 layer from 2 (thin and thick w/glue). I find my gaffs to be a tad thicker because I use the two thick halves and sand down the thickness a bit before gluing them back together. This also stops them from being see thru. Most of the gaffs I make this way, the spec will never touch so the tad extra on the thickness is no problem, as a matter of fact it helps me as it is now a "thick card" and can be easily controlled.

For gaffs I make that the spec will likely touch. Like Chessman stated, I use DMT (dry mount tissue) and a small temperature controllable iron (from a hobby shop used for decals on remote control. There is an excellent ebook on Lybrary.com for DIY dry mount gaffing
http://www.lybrary.com/the-gaff-factory-......750.html