Form having abutting tape-interconnected substrates and method of making same

A method of forming a business form product of multiple substrates, said method comprising the steps of:

• (a) feeding a first continuous substrate web along a longitudinal path;
• (b) feeding a second continuous substrate web along the path;
• (c) aligning the first and second webs in an edge-to-edge relationship to form a seam therebetween, wherein the seam extends along and is at least generally parallel to the path;
• and
• (d) applying a continuous streamer of tape to the webs over and along the seam to retain the webs in said edge-to-edge relationship to thereby form a common continuous sheet,
• said longitudinal path being defined in a rotary press,
• step (d) including the step of feeding the aligned webs and the streamer of tape through a nip roller to apply the tape over and along the seam,
• step (c) including the steps of aligning at least one of the webs with a mechanical guide prior to feeding the at least one web through the nip roller,
• said mechanical guide including a shaft and at least one collar that engages one edge of the at least one web to thereby align said at least one web in said edge-to-edge relationship with the other web,
• said at least one web being within at least about one-one-hundredths of an inch from said other web when in said edge-to-edge relationship,
• said mechanical guide being positioned upstream of the nip roller and located within one foot of web length from the nip roller,
• said at least one web being at least in part formed from magnetic material,
• step (c) further including the step of feeding the at least one web through an idler roller prior to feeding the at least one web through said mechanical guide,
• said idler roller being positioned at least four feet of web length from the mechanical guide.