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I agree with Accent signs and Stacey K - leaving 1/8" or so around the vinyl works best for me, especially when the dibond sign I use has a couple rough edges along it.
I was in the same predicament with my Mimaki CJV 150. Opted for print head replacement, then fuses, then circuit boards, $5000 later nothing worked, still was billed because new print head was probably fried, and ended up buying new HP latex printer. Could have saved myself the $5000 if I went...
I had overspray for a couple months during cold spell. I bought two humidifiers, static string and use RainX to spray on my Mimaki CJV and it worked incredibly well. I did not think static would affect printing as much as it did. I'm sure it helps temperatures warmed up now but my humidity then...
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