I'm busting a gut here... you guys kill me. That scale pilot is so life-like.

Funny it doesn't have a terrified look of expression. [X(]
The graphics job on both Tr-Pacers are cut from monokote. I would have done it with Ultra-cote for the low heat properties, however the colour I was after was not offered in Ultra. I had to be very careful to apply it with an iron. I touched the ends of the graphic piece with the iron to secure it, then I made short contacts in a few places. You can't just iron it on there. The co-polyester will want to make a nice corner for you. So I tack it on the cowl with minimal effort (if its position is off then it can be zipped off and re-applied). Then I remove the cowl and lay it flat. There, I can iron all I like (well, I try not to catch anything on fire). True a light slip of water with a drop of soap really helps the graphics go on nice and flat, I used a spatula to squeeze out the water - less scratches then a card.
I cut one set of graphics (the black and white version having load testing done) by hand. I made a design on the computer, printed it out in tiled sections, taped the whole thing together over the monokote - on top of a foam slab, then started cutting with a knife. The process was long, but worked quite well. The second version (the one on the cover of the manual) was cut on the laser. Boy that was a lot easier!