Portfolio Size: I definately prefer smaller than the standard 11x17 portfolio. My last one was 8 x 5, which is not so small that you cannot see the images , but when you open it up, it gives you nice long page layout, which helps for story-telling of the projects.
Other graphic materials: Business cards and DVD covers should match the portfolio covering. Since, I am going for the laser cut cover , I think similiar approach would be nice for the rest. I love the chipboard business card above-it looks so raw and at the same time perfect. And , it will be fairly inexpensive and easy to do.
Here are some examples of my previous graphic layouts and what I am going for: