It turns out that:
1- I just needed more time to learn my heat press. I upped the temp a little more and applied more pressure.
2- The epson printer just wasn't cutting it so I purchased an OKI 3400 laser printer and use Dura Cotton HT paper with it.
if found this solution perfect for making pro grade shirts everytime. Not more hassle/experimenting and wasting shirts, ink and time.
I have been pressing shirts ever since that post with the equipment listed above and after Countless washes t-shirts still look like new - vivid colors.
I know laser printer costs more than inkjet (oki 3400 currently costs $234 on special instead of $400 at
tigerdirect.ca) but I found you can't even compare the quality of both. Another HUGE bonus is that with Duracotton HT, there is no need to cut unprinted portions of the paper, just print the sheet and press. There is no box effect at all.
Hope this helps!