WOW. I will be referencing your post in the future!
Thanks for the info, I am going to be doing some tests today. I will try using some lower lpi. I will make my own alpha channels for my splits. I'll keep you posted on my progress.Your skin tones were hard to achieve because your halftone count was too small. 85 line halftone is very hard to do manually to begin with and depending on your emulsion you likely lost key blending effects that would have happened better with a slightly lower halftone count like a 60 or 65 line dot, also if you set up your angles to all be at 22 degrees you will stack color and force a nicer blend on the shirt. With discharge underprints the manual press is certainly a good option for what you did. Photoshop tends to add black into skin tones on cmyk images. You might want to try and simplify your separation process by creating your own alpha channels in photoshop and pulling your desired colors into spot color channels based on just the colors and shades you want.