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This is a key problem. It's all well and good to offer great design but most of my customers don't know the difference between great design and crap. They do know the difference between cheap and expensive though. I could move I suppose.....
Gild 'em.
I'm with Mosh...selling them a new sign would be the best option. I think painted brick would look bad and you're screwed if they don't like the finished result.
My cheap-a$$ drag knife plotter cuts great at the highest speed it has. I don't think a good brand name one would do worse. Maybe it has a "pounce" setting? Or like Fatboy said..... you got a new bad blade?
When did the trouble start? Right after you made some change or did something different?
I hate dickin' around with registration marks. I always weed off one or 2 of them anyway. I find it easiest to wet app the top layer by eye. I have a better eye than my customers so it works for me.
Lately I've been doing more wet apps. I can do dry apps all day long ('cause I'm a macho, he...
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