I think i figured it out, i was reading a bunch of threads about this issue and finally came across one that explained that the point of the ground strap was to remove the static from the vinyl via the rollers, and suggested checking continuity from the ground strap to the rollers... surprise surprise, i had none... so i rigged up a ground strap for the roller, i just loosely tied the wire around the roller and then braided the wire... since its loose it doesn't inhibit the roller movement, but it does create the grounding needed, i re-cut the same design again and it worked fine.
thanks for everybody who contributes on these boards, couldn't have fixed it without the suggestions here.