Here is a process set of pics going from stencil to art print.  The printing was done up in Portland at Diesel Fuel Printing during the Vinyl Killers 5 show. 

Big thanks to the guys for letting Klutch and myself hang out for the day and see it go from start to finish.

Here are the steps from stencil to print

1) Start with your final stencil piece that you want to make into a print.  This is "The System Works" from 2005.

instead of scanning the original and dealing with color seps I just busted out the old stencils.

2) Stencils

3) Spraying - I spray everything on white paper using just solid black

4) Scanning - since these stencils are all small, text is about 10 inches and the corporate vandal is about 3.5", I scan them at 400% and 300 dpi

5) I take the separate scanned images then run them through the threshold option and clean up any little bits and pieces (I have no shots here but if you need that I'll take some)

6) I make the print file which will be 18"x24" and make the working area 16"x22"

7) I take the solid image of the man and move into the print file and once adjusted for size and positioning punch it out of the background color since the paper will be the white layer.

8) I take the other layer of the man and match that up with the punched out layer.  I also do some editing as I wasn't keen on his hands in the first one - the next group of corporate vandals will have hooks I think.

I also bring in the text, fill in the bridges and merge that into 1 black layer.  I messed around with red text in photoshop but didn't like it at the larger size and the black text just looked stronger from a distance.

9) Make the color selections using Pantone chips and label the layers appropriately.  This image only has 2 layers so its not that big a deal getting everything in line.

10) Send files to Andy and then sit back and wait or go up to Diesel Feul and watch them make it.

11) Stop briefly to sticker the dumpster beside the door

12) The separate layers are then printed out to film for burning

13) The print monkeys get ready to work and form their plan of attack

14) I'm just throwing this in here to make people crazy - here's an old original Swoon from one of the Process Invisible shows with a new head in the shop.

15) Screen is coated and burned

16) Screen is dried - note the large power cable on the floor as safety is first.

17) Ink is mixed by eye to the chip specs

18) Screen is in place in the press and the ink is applied to the screen

19) First one comes off and we inspect for any flaws

20) After 1 minor adjustment the run begins

21) Stack of the prints with the first layer down drying

22) Lunch across the street

23) repeat step 13

24) Black layer screen is burned

25) Second screen is registered with the first layer and the process begins again giving the final 2 layer print.

After the final layer prints are sent to the cutter, boxed and then shipped out.