Update -- My current printers have now outputted the file to film again, and it turned out fine...I have no idea why it didn't work the other 2 times, but I'm just glad it works now.
It's going on press on Monday. I'll post back with a pic of the printed cards.
I'd just like to say thanks to everyone (except pointyhat ;p) for their help, especially Joe.
On the plus side, I've learned so much more about prepress trying to fix this problem than I would have if everything had gone smoothly. Every cloud....
Cheers guys
