Thanks for the help all... I did a lot of paper flashing back in my days as a newspaper photographer making screen prints. was never really a fan of that technique, but were doing it in a pretty low tech way.
Been chatting with Alan Ross and he's given me some great suggestions... He thinks selective masking is the way to go on it.
just got his CD's on VC Printing and Masking, can't wait to get into them to start working on the next series.