Lots of great ideas floating around how to complete this project. Thinner border, extra labels, change this, add that, etc. All very nice. As much as I would prefer printing right on the Sys, I realize that it doesn't seem feasible anymore from a quality perspective. If the printer can't center the printing side to side on the Sys, that's a deal killer for me. That's a lack of quality control I am unwilling to accept. Up and down, don't really care. The ink bleeding should have been expected by everyone. You can't print fine on a textured surface without some bleeding.
At this point, this project has to be eating up Peter's time and life like crazy. He didn't have much hair to start and probably has less now. [eek] One could say (not me, just voicing devils advocate) he should have done more printer research to avoid these issues. However there is always a learning curve and sh_t happens.
It's time to bring this project home. I would suggest Peter take all the ideas into consideration, assess the best options, pucker up, make the best decision and move forward. Grab it by the _alls and make it happen. Provide a good quality product that looks good, lasts and is reasonably within expectations. Guys may moan a bit about not getting exactly what they wanted or expected but they'll be happy.