Method of making a self mailer with return envelope formed from a single cut sheet

A method of making a business form construction printable in an impact or a non-impact printer comprising the steps of:

• a) providing a base sheet of face stock having a front, a back, a top, a bottom, and first and second sides;
• b) placing a first line of weakening adjacent and parallel to the first side of the base sheet to define a first tear strip on the front of the base sheet between said first line of weakening and said first side;
• c) placing a second line of weakening adjacent and parallel to said second side to define a second tear strip on the front of the base sheet between said second line of weakening and said second side;
• d) placing a first transverse line of weakening extending between the first and second line of weakening;
• e) locating a lateral strip of adhesive between said first transverse line of weakening and the bottom;
• f) applying adhesive to the first and second tear strips, and applying first and second thin strips of adhesive just inwardly of the first and second lines of weakening, respectively, between the first transverse line of weakening and the bottom;
• g) folding said base sheet along a base fold line to define an envelope pocket, said base fold line being located between the first transverse line of weakening and the bottom;
• h) printing information on a portion of the front side between the top and the first transverse line of weakening;
• and
• i) folding said base sheet upon itself between said base fold line and said top to enclose said envelope pocket;
• wherein steps a), d), e) and h) are performed before step f), and step g) and i) are performed after step f) and before steps b) and c).