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It wasn't really as much as "how can I fix it". I have found that if I turn overprint black OFF in the rip, all is good.
The shirts in Illy are made up os so many layers, i can't really find any overprints.
This was just more of a "have you ever seen this" type of thing towards the forum and maybe be aware of it with Illy CS2.
This is going through Preps also and maybe if I imposed the file in Indy instead, it may have been fine... some more work on my part to find out. I'll post my findings by the end of the week.
Thanks all for the input.
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