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Laminating Inkjet prints is a must. Sounds like you would want to laminate the Edge prints also for durability and u/v protection if the sun is that harsh.
There has been a lot of threads comparing thermal to inkjet. You may get more info from a search since this subject had been around the block so many times.
Take a look at Gerber's site, there's a lot of information there.
http://www.gspinc.com/
Scroll down to literature and multimedia under the thermal transfer tab.
Load the material and make sure the crop marks are over the cutting strip area. It should scan the front marks then advance the material and scan the back.
What is your document size? What is your font size set at in design central?
Sounds like you have a large work area with very small text and you just can't see it.
Flexi's driver is set at 1016.
Make sure your curve quality is set to high.
Sometimes imported eps files come in with an extra path. Zoom in close and check your artwork.
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