@pboland I am interested to see if your method works out for intellivision.
I had a site bookmarked about how to make overlays, and going by memory, they used acetate sheets, like you would use on an overhead projector.
I'm going to be totally open and honest here, so please don't be offended. I think part of the issue with making overlays for any system (INTV, Coleco, 5200), users are stuck on the idea that it must be printed on plastic sheet. After all that is how the originals are made. It is this reason that it is so hard to make overlays. It is not a common practice to print on that type of plastic any longer, so most places are not equipped to do it.
The method that I use to make overlays was developed by me about 10 years ago, because of looking into plastic printing for my Intellivision collection that I owned at that time. Though I'm not printing on plastic, my method does allow a much better printer quality then you would ever get on a plastic acetate sheet. I do print on a very high quality paper and than laminate the paper. By laminating the paper it gives it a similar (not exact, but similar) feel to the original and a durability that is needed to be inserted and used over and over again. Also, there are two more benefits over the original method. The first is the image doesn't scrap off from behind like the originals tended to do and most important of all (for me anyway) is I can make them on demand. I don't need to order 1000-5000 at a time.
Also, up here in Canada, they've started printing 100$ and 50$ bills on plastic, and 20's will be released soon.
Whatever plastic they use in that process would be perfect too, I'll see if I can find the exact plastic they use, its some kind of polymer.
That is interesting information, but I don't think it would be a good idea to try and find out what plastic they are using and how they are printing on it. I don't want people (or governments) thinking I'm try to counterfeit money. After all Canada is doing this (from my understanding) to cut down on counterfeiting.
Cmart can probably weigh in on this too, I'm sure he's had a few pass through his hands by now
I look forward to him weighing in. I believe he bought a set of my Colecovision trading cards from me. My method for the overlays is very similar to the way I make my trading cards. Meaning the lamination process is very similar.
Would you be open to possibly doing a whole new set with new artwork, or were you mainly looking a reproducing existing overlays?
I tend to use the existing art as a starting point, but I find most need to be "cleaned up" first. I basically redo the image like I did in the overlays posted in the first message. I don't like just scanning in an overlay and hitting print. If you want an example of my "clean up" work, you can check out this topic (no, it is not Intellivision, but I think you get the idea):Colecovision Labels Thread
As you can see from the link above, I do rework the art. This is done not only to clean up the images, but to also make them more friendly to my printing methods. I hope that helps.
On a side note, Would you be interested to do some testing for my overlays?