Good post! Many people getting their first bitcoins need to know this stuff.
When I did this years ago, I bought a used IBM Thinkpad for $100 and that is my paper wallet computer. It is never hooked to the Internet , and the bitaddress.htm file was saved to a USB thumb drive from my regular 'net PC, and said USB was used to launch the paper wallet web page offline on the Thinkpad. The other thing I did is not encrypt my paper wallets. Why? Simplicity... what if my state of mind is different 20 years from now? What password? Where did I put that separate piece of paper? What if there is an issue accessing a suitable decryptor? My way is equivalent to storing cash. Hide it well. You can make your paper wallets fire & water proof by etching the private keys on a piece of metal.
Very interesting! Let me see if I fully understand your method. So the Thinkpad is your offline wallet and the USB thumb drive has the web site bitaddress. The UBS can be used in both the Thinkpad and your PC. This is genius!
Not sure if I agree with not encrypting. Although I do see your reasoning. I think I am going to go with actually printing multiple paper copies as well. As soon as I can things figured out for safe storage.