Interesting, J-money. Being in the north, I don't deal with real high humidity and temps generally. I had no idea those two things can affect exposing. Screens that is. I know some people have an urge to expose themselves when it gets hot out :o I can't speak to how much longer to expose for as I ha...

Specifics vary. It basically depends on your flash dryer and how many layers of ink. It'll take a little experimenting to dial it in. I would suggest maybe just adding a couple more seconds. Use a temp gun and make sure it doesn't reach more than 280 degrees F (133 C). That should be enough for most...

I'll say it's probably a combination of things. First thing is that it's probably under exposed. Using household chemicals can leave behind residue that you don't want also. Having a scoop coater would also help achieve an even coat. You probably have some spots with thicker emulsion which might not...

Plastisol or water based? Either way, 165 could be high depending on ink and design.

When I print transfers I semi-cure under a flash dryer after adding adhesive powder. Just long enough to dry the ink to the touch. Letting them "air dry" won't cure, or semi-cure, plastisol ink. Also increase your temp. I'd go at least 170 Celsius. Heat press temp can vary a little bit so ...

For short runs it's fine. But over time the emulsion will breakdown on the screen. You want either a water resistant emulsion or a hybrid. You could also buy an emulsion hardener that makes emulsion more resistant to water based inks.

I wouldn't eat or drink any Seriously, you have a better chance of any risk burning yourself on the flash dryer. Which should be less than a 1% with some common sense.

Are you flashing between print? If so, make sure the ink cools some before hitting it again with ink. Printing on hot ink can cause the ink to semi-cure in the screen and the printed ink will be sticky. That can cause your screen to stick to the print, resulting in poor quality.

Can you post a couple pictures to show what you mean? Maybe one at the beginning and then the end result.

Basically, it's removing the dye that's already in the shirt and replacing it with the colored ink you want. The result is a print that feels just like the rest of the shirt. It's a cool thing but it does require additional steps and precautions due to the chemicals used.