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You can probably save the job.
If you had Versaworks handle the arrangement within the nest job, or if you arranged their order by hand but had Versaworks compact them automatically, then you may be able to recreate the same arrangement get them back.
You want to make sure that the roll width...
Knifeless tape looks like a great product. Is it pretty widely used and appreciated, or does it seem more like a flaky gimmick with inconsistent results? If it doesn't work right, I can see getting rips and stretches in the vinyl.
You could do an initial hinge by cutting away an inch or so of backing paper along the edge of the panel, and pressing that section down by hand or gently with a felt squeegee. Lay the rest of the vinyl on with the laminator. Laying vinyl with a laminator is awkward until you sort out how to...
If your bounding box is set to objects, there may be white or transparent objects in the design which aren't visible printed but which still affect the boundaries of the artwork. This happens with EPS. Try a clipping mask (or in Corel, a PowerClip curve) over all the artwork.
Dialing in CMYK values in raster print files
I know this thread is pretty old, but I didn't see anyone mention the following technique and I have found it to be very useful. (I know your problem turned out to be something else anyway.) If you have the CMYK values you want to hit for that...
We had a similar issue on our Roland, but only for the first foot or so of any given run. It occurred when printing on vinyl or static cling. Our tech said it was residue coming from a slight decay of the rubber on the inner rollers, and advised us to only use them when cutting.
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