Steve,
Thanks for the tips. That is a pretty good idea for bringing the blue on the underside of the tip and giving a straight line break. We used ultracote on the bottom cause that's all we could find for the checker pattern. We used Monokote on top cause Ultracote is so expensive. We did find the Ultracote more forgiving. Guess that's what you pay for!
And you definitely are correct on the checker being a challenge to keep straight!
How's the search going for your BBS?