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As for the emulsion coating it is VERY important to get a smooth even and consistent coat on your screens. Putting multiple coats using the round side of your scoop coater will cause your exposure time to go up significantly. A thicker stencil hold better detail, higher resolution, lasts longer, and allows for a more opaque ink layer on the shirt. If you have a weaker light source - you might have to use a 1 coat print side, 1 coat squeggie side with the sharp edge of the coater.

Also, if the film ain't TIGHT against the screen, you'll have problems.
 
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