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Color format depends on project, printer profiles and end results needed. Most rips will take RGB/Spot (PMS) to CMYKLcLm since mainstream large format printers are not going to have Red, Green, or Blue ink.
As far as you being able to use an Adobe Illustrator file, it all depends on your set...
As production person I would:
Type out the font
Right click and 'create outlines'
Use a white outside stroke to the desired size
Expand the stroke so it it's own shape
Use a black outside stroke on the white shape
Expand the black stroke and combine them into one shape
Done
.
Depending on the project, what you can do is you can take the individual objects and copy them form Illustrator and than past them into Photoshop as smart objects. This might be a better solution as than you can use the masks and layers to have more control over what your doing.
But you...
Why not just do a pillow cut or a bleed cut to shape, Would this not have worked better and this way you wouldn't have had to worry about the color match?
Was just thinking about all this and it might be a mute point, will the school even allow you to have a printer on premise? Do they have any guidelines for whats maybe allowed? This might help you decide.
Depending on what materials you using they should come out after a few warm days. The adhesive will flow and even out. You can assist this with a heat gun and post heat when you done. We've done building that looked kinda looked like what you have and after a few days you can't even tell.
So did you buy a printer had have no idea how to use it?
Do you have a laminator?
As far as you questions go. I would say it's the designers job to get a template. But there are several vehicle template services that you can subscribe to or purchase online. I've never had much luck with...
There are many many suppliers everywhere. Try to go local if you can. Your in Oregon, so you should be fine with lots of options. I know one supplier in Oregon is Sun Supply.
So you should look at latex. You can let it sit there for a a while, it will print onto almost anything, no fumes or waste ink to deal with. Ready to go as soon as it prints.
If you plan on printing in school you I would stay away from eco-solvent or solvent as it doesn't do well with being...
Remove the emblems and store them someplace in case the customer wants them (few ever do but you never know). As far as the door handle goes, on the chevy's it's just a torque head screw that you can unscrew to release the handle (takes a few seconds make sure not to back the screw all the way...
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