Hello Ger and Rick.
I find picture I like , Photoshop till it is as close to stencil like , i.e. black area needs to be connected . what I can't get in PS I do with Aspire, Node edit ( VCP would work) I then cut in .25 MDF you can get thinner lines if needed ( if vectors nice and fat use .125 HDF cheaper
Flat black is best. I just use black primer drys fast and is flat .
Hope that is not to simple if need more info please ask.
please post if you make something