One thing I'm wonder about there is the layering of paint types. The covering(s) will absolutely be filled with water-based Polycrylic. There's no way to avoid this as it's vital for the process. And then I need to put down a white grid background and then the black crosses on top of that.
I had been planning to use simple latex for the white background, but isn't enamel on top of water-based paints a no-no? Would I have to use enamel for the white too...and would that white enamel bond to the PolyC?
(I need to dig out the compatibility chart that TFF posted.)
enamel over latex has never created a problem for me, done it plenty, thinning the paint when your painting anything is the most important part specially in hand lettering, it takes a little practice and doing to understand how important that step is, that is why the majority of people go wrong and give up.
On your first question... I would do this, make the traceable pattern of the Pattee as I discussed earlier first with manila folder, after that make a masking tape "sheet" oversized then the Pattee by taking the "green" 3m masking tape and overlapping it say by a 1/4" or use 2" tape much better/less seams. Any good tape works for this - DO NOT USE cheap tape ever for this process ever, most of the time I use a Transfer tape that is used for applying vinyl lettering it makes an awesome mask, but it might /probably wont stick to well on the fabric. OK now do this process on a hard flat surface that you can cut on, then squeegee down very good. lay/tape your pattern over the tape, pencil around it or hit it with a "spray can" any color will do so you have an outline, then cut it out with an exacto #11 with a new blade (VERY IMPORTANT STEP in cutting any mask), now peel the background off and pitch that, now you have a "male" stencil. OK, lay your box out on the plane wing/fuse with a pencil then tape that off just outside the line so the paint will cover your pencil, next peel your stencil off your board "carefully" so you don't stretch it out, stick that where you want that -squeegee down the edges pretty good. now paint your white background, peel tape back off, now you have a silhouetteof the Pattee. Let that dry then free hand the Pattee.
Now putting latex on an enamel bkgd. you could have a problem with it adhearing, you would need to scuff the surface really good to get any life out of it.
well hope I didn't confuse you, oh for that paint and transfer tape check out all the sign shops, they might just give you some?? it dont take much paint and tape for these projects.
On Thinning the paint... hope I explained that right, didn't want you to think that you just thin the paint with kero, that is just an additive to the paint not a reducer, a cheap alternative to Penetrol, So you need Paint, Thinner, and possibly the kero., its only a maybe thing if your having a problem with it too tacky. If your layering paint NEVER
put kero on the bottom layer
you will have an ocean of fish eye's on your top layer if you do!!!
The 38 and the Hoover 51 is for Murray.....