I can't tell from your post if you are printing out in the correct size or not. Assuming you are getting the right size, I would recommend using a thicker pager that is more rigid than normal copy paper. Then, I use a sharp knife to score a line where the paper will bend for the corners. You have to run it very carefully to score the paper without cutting through it completely. Then I just fold it into the jewel case. I some times use the back of the knife blade to run it through the crease again once it's in the jewel case to make a nice tight fit (again, being careful not to cut the paper). If it isn't tight, you aren't printing to the correct size. I pretty much always have an original PS1 insert nearby for checking the overall size to make sure it's accurate.