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I went from XP to windows 7 w/ Flexi several months ago at an older job and we had no issue w/ 7 supporting us.
At home I use CS4 and the cutting master plugin (reads free) to output to my plotter here. I was a diehard flexi guy for about 10yrs and once I became more involved w/ designing for...
We peel the print back and cut the liner w/ scissors. W/ a calendered air egress film, there's no issues w/ lines. We mainly ran Oracal 3165RA as our 'standard' digital print film.
I've seen some haziness in prints from what I was told was not proper outgassing, but I've definitely hung vinyl that was gummy and bear to install from going straight to laminate.
I'd do cut vinyl if it were me probably. All the setup for screen printing (25) is pretty high. If I didn't care how long they lasted I'd just do them on a UV flatbed.
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