 Re: 4 colors and 6 pressings
Each color has to be cut seperate. The lettering was straight forward.
The block design had three colors. I used the white block as the base and outline. In the original design, the outsides of the white were perfectly even with the outside of the other colors. I deliberately expanded the white a small amount so that all of the others pieces would be inside of the white. Both the other two colors had straight edges to them. By expanding the white, this allowed me to press the white first. I then lined up the other two colors with an equal amount of border on each side. That gave me a "guide" that would ensure that the rest of the design lined up.
I explained what I was doing to the customer, and why. Before cutting out and doing the actual work, I made a small sample that I showed the customer. They looked at it and approved it. Having the extra around the outside gave me a little room to fudge if needed.
As a matter of fact, they called me again today and complimented the work again. They wanted to make sure that I checked my email.... they had just sent a request for me to work up a proposal for 50 t-shirts, 150 nice wicking polos (embroidered) and 150 caps (embroidered)for an upcoming golf tourney.
We have done work for them in the past also. We did dress shirts for them. | 
