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What media are you printing on? We use mostly 3M and generally don't have any issues.
Have you taken the time to set up you own media profiles or are you using stock ones?
What are the conditions in your shop? Is it dry, humid, cold, etc...
As far as the issue with grey...
Are you trying to...
I used to use these with Red Bull. The back is lit with a flat diffused LED. They were smaller but same thing. I'll reach out to my guy to see if I can get a name or manufacture.
Some people don't want either of them on their vehicles as they can look dated or tacky and some don't age well in the sun. The deflector is more for windshields and hoods not bumpers, or quarter panels.
In some areas where they lay down gravel for ice and snow, tires kick up small pebbles and rocks that take dings and small nick's out of the hood, front bumper, and front quarter panels. This leads to paint issues down the line and re-sell issues.
There is material that is specifically made for this. Several manufactures have them including 3M. If it's not something that you do regularly than I would suggest you farm it out. It's a bitch.
I have found that saving to a flash drive often creates issues. Your better off saving to a local hard drive than copying the file to the flash drive. If it's corrupted than I don't think there is much you can do for the average person.
Depending on how much coverage but most chrome won't go over rivet as it's not comfortable. You will need to get a chrome made for vehicle wraps which is not cheap. I think Avery sells one.
I'm rocking two HP 570's and have no issue with 'graininess'. Small text is also not an issue. A lot of it is about having the right profiles for your printer and media. Some times this can take some time and material and needs to be regularly updated which again can take some time and...
Congrats on moving to latex...
Designing in Corel is fine. As far as rip software there are several out there I would suggest getting trial versions to see which one works best for you. There are several threads that are dedicated to this topic.
As far as your second question, Latex is fine...
We don't do first or second surface we print both first surface. First you print onto clear apply it to the plex, than print onto trans, laminate it and apply to plex over top the clear layer. It works best with a light table.
Print onto clear, apply to plex
print onto trans laminate, apply to plex ontop of the clear. A light table would help with getting everything lined up.
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