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Gemini sell steel studs and I know you can find them elsewhere

No offense, but that is a basic general liability insurance policy that everyone in business should have. In the time it took you to write your post, you could have sent an email to your agent with client CC'ed and you would have trumped their BS. Do they need it, NO, but corporations with...

Usually try and avoid it, but if you have to, clean it well, then flame treat it with your torch (Corona treating), clean it again, primer the edges, and post heat it when your done. No warrantees given.

Onsrud single flute spiral O's. We used mostly 1/8" and some 1/4" until the day we figured out they made 3/16" stubby ones for 1/8" aluminum. That was a beautiful day.

We didn't try downcut bits for very long. Any time we cut something with adhesive, it would get stuck on the edges and created lots of extra clean up. A cleanup pass may have taken care of that but we primarily used single flute upcuts so we moved on. You can also try masking it and cutting it...

If you can't find the exact colors you are looking for, laminate it with vinyl and mask it a couple of times. Then, route it face down. If you route it face up, you will have a lot of vinyl fuzz to clean on the edge of the face. If you don't use the mask you almost have to surface the table...

99 times out of 100, you forgot to order a templet. It costs extra and they aren't going to include it if you didn't ask for it. I deal with this all the time. We order stud mounted lettering and the condition on-site won't allow stud mounting. In that case, we tape up the templet and then cut...

They do that without vinyl especially when the seals around the doors are bad. there is cheap plywood behind the thin metal and it gets wet and holds water. Typically the lower sides and bottom are the worst.

If the masking tape won't hold up the graphics, it's the paint. You can try cleaning it with diluted alcohol multiple times but you run the risk of changing the sheen of the paint. Scuffing the wall with a scotch bright pad or sandpaper helps as well. All the solutions are time-consuming so I...

Try Ash (Regular) and manually squeeze and slant it.

Switch to Avery and make sure you leave an 8" gap. Focus the heat (which is where the stretch will come from) away from the indentation you are trying to tuck it into. Avery can conform without failure with this method. With 3M, the stars have to align for it to work. and if it does the...

We used to do the same thing with yellow and silver using Rolands. I would assume it has something to do with the ink loads. We printed black on these colors for aviation placards and I'm guessing the solid black would mask the issues your having. You could try cleaning it, but your just as...

You can also heat the text with a heat gun and then it will shrink back as it cools. Setting it out in the summer sun works as well. Also if you cut a bunch extra, play around with speed weeding. I think the vinyl senses your fear, so grab an edge and jerk it off like you don't care (135 deg...

Because men marry women hoping they won't change, and women marry men hoping they can change them...

You might think about selling them the equipment and taking a commission off all the clients you bring with you.

Did it happen overnight? If so it could be your capping station. If it happened during the day after a successful print try the fuse.

You might try showing them the price for what they are requesting and show them a price to print the text color on a bar with the text the white of the vinyl. Then, inform them that text that small will have durability problems. Sometimes with a couple of good rationalizations, you can steer...

If you use air egress vinyl you're screwed no matter what you do at that size. I feel your pain. Andy D's method can be a big help as well.

Reverse weeding is great, but if you're installing the logos, weed them on the vehicle after you install the graphic. Either way, I usually will select the text, convert to outlines then fillet, or round the corners slightly. Letters that small it won't help a lot, but I find that sharp corners...

Forgot to say that the colors won't be as bright because all windows have some level of tint. Stick with high contrast images and the graphics will still have some impact.