Essentially a 60 will work for everything, only "danger" is that the tip is smaller so it's easier to break it, but so long as you have the depth and pressure set correctly that shouldn't happen.
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Never a pain, and it's much better to have extra blades, than not enough.
That being said, even though you might have stocked up on a bunch of blades - it is worth looking at Clean Cut blades if you did buy those. Not all blades are made equal.
You've ruled out static as the problem with the pen test. Have you tried different software or cables? Are you using a USB cable or serial? Serial is a better option if you have one on your computer. If not, you can get a triplite keyspan usb-serial adapter.
As for tracing, I'd find the state outline, they're pretty easy to find, and then manually trace the letters, they're all straight lines so it shouldn't be that hard.
first - your best work yet!
did the first onsie say "just did 9 months on the inside?"
or the one with the pacifier that read "say hello to my little friend?"