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Put a strip of double-sided tape along the top and bottom of all windows (on the inside obviously) and stretch a piece of black banner between those.

I assume it will be a "permanent" application; if so I would use some Arlon DFP8000 for this project or the Avery (air release) high tack vinyl if you are not that experienced with install.

Make sure your swear jar has some room in it!

We use Silver Medal a lot on truck doors and it hols up long term, but we laminate with 3M 8519 laminate. I would assume a clear coat would do just fine also.

I also 2nd OnOne perfect Resize, it "should" make these usable images. I have used ones that bad before when the customer provided them.

I'm pretty sure you're gonna have to hand draw that.

Any other ideas? Kabel seems to be close and Kaapeli is close also, but no exact match yet...

I haven't ever seen a font with "E"s like this... have you?

The "f" has a funny little part where it takes a turn towards the top, but the rest of the letters look pretty close to Cheltenham.

I keep finding very similar fonts, but can't nail this one down. Have to match existing signs with new signs.

Keep using your same RIP if you can, We run Onyx RIP here for all of our printers. (HP, Mimaki, Epson)

Get a magnifying glass or loupe and look at your blades. I am willing to bet that both are bad. We go through a lot of vinyl here and sometimes the Mimaki plotters blades just randomly break. You shouldn't need your blade to be sticking out that far, but we normally run on 100 setting on the...

Yes, definitely the YelloTools one with the teflon pads.

You can put the software/dongles on ebay, as they are worth decent change to same money off an upgrade to newer gerber software. The hardware.... might be good for parts. Gerbers run forever and users are VERY faithful so someone may need them.

PP Board? (lol) http://www.ptonline.com/products/hollow-pp-board-is-one-inch-thick

Alumacore?

Can you use a rounded dashed-line stroke following the center of the line, and then do a shape merge (pathfinder tool in Illustrator) and only keep the overlapping areas? (Sorry, I have never used Corel, but I know this is how I would do it in Illustrator)

We have used some of the "non-adhesive" sticky vinyl before, and while it works great for smooth surfaces, I would not think that it would work well for a moving vehicle; especially one where the driver is installing it their self.

Would Ghost Off work the same way it does on old box trucks in this instance?

I know a great local independent Mimaki tech. Not sure if he travels as far south as you are, but he MIGHT. I will PM you.