Making decals is a breeze. Try it once and you'll have it mastered.
This webpage at BareMetalFoil explains it all. Make sure you use the liquid decal film, as it keeps your decals from falling apart when you apply them. The decal film is super-easy to apply: I just use a big foam brush to spread it around on the page, then it self-levels sort-of like Future. No need to airbrush it. And I always go with the laser printer paper instead of the inkjet variety. Maybe there are inkjet printers that can produce results comparable to laser printers, but they are rare and expensive.
http://www.bare-metal.com/Experts-Choice-Decal-Film.html
Also, it's supremely important that you draw up your decals at 300 DPI or better. Photoshop (and most other image programs) start you out with a default image resolution of 72 DPI. That's the perfect resolution for web graphics, but if you ever want to print out your image it will look very pixilated at 72 DPI. 300 DPI is a good size. Then getting the sizes right is just a matter of scanning another decal sheet at the same resolution (300DPI) and using it as reference to scale your custom decals. I usually try to fit my decals into a 7.5" x 10.5" area which allows for a 1/2" page margin. Lastly, you want to make sure that the employee running the printer verifies that the image prints at 100% size and is not "scaled to fit" on the page. Also, i've found it helpful if this employee is an attractive college-aged girl.
You have to be mindful of whether or not you need to print your decals on clear or white paper. Yellow SL numbers printed on clear decal film will work great when applied to a white surface, but they will be almost invisible when applied to a dark surface. You might notice that I have printed out some white silhoettes of the Boise Bee markings to go behind the actual decal.
Hope all of this helps! I'd be glad to help you with it. Making your own decals really opens up a lot of new possibilities in this hobby. Let's see, on that decal sheet I have:
- Custom nose art for a "what-if" P-51H scheme
- "Boise Bee" markings (scanned from ICM decals, which silver horribly. Mine wont!)
- Custom decals for a Bell-212 heli-ski scheme
- Decals to apply to the wood base for my B-58
- SQD and SL numbers for my P-51A build
- Spitfire markings for Jonnie Johnson's Spitfire IX
- Tailband for a 388th F-16C
- Aircraft numbers for a KA-50 Hokum
ALSO:
- A bunch of extra P-51 stencils, since I build a lot of mustangs
- various sized USA and Canada flags, for general use
- A whole bunch of "no step" stencils in various sizes (always need these)
- General lines of various widths (some dashed)
- numbers, letters, on and on
All from two decal sheets and about $10 invested.
4 hours in front of the computer screen though