[Bob Brown]

Reading over the thread I see about everything that I have tried.

What I have found works great is this. I have a vinyl stencil plotter for making decals. Not hard to find. Any sign maker has one. I don't want a decal on the paint I want it painted on...so

What I do is I use a non permanent decal stock and do the decal on it. I then take out the letters (opposite of what you would normally do). This will leave you a stencil that you position and stick onto your vehicle. As I leave a couple of inches of material I mask (butcher paper) with green painters tape around it on the decal.

I have hand painted and I have spray painted. Both have looked good.

Let it dry a little bit before you pull the stencil off. Nice shape lines.