Jacob:
I talked with pcbfabex and my suspicion was correct with regard to the silk screen issues. Minimum is 6 mil, if it's less than that they try to resize it, which as they said, often results in fail. They said maybe even go up to 7 mil. This applies for the lines as well as the lines that compose the text. I'm not sure what 7 mil corresponds to in "font size" ... who knows.
Everyone else:
I'm going to talk with Dan soon and we're going to need people to firm up their board quantity. Probably best to do this via PM, so be on the lookout for this.
I've talked with four places, all seem very eager for my business. I have two more board runs to bundle with this, so I'm trying to leverage all of them to get us the best cost, and to finalize the quote I'll need to firm up numbers, hence request for participation.
Specs I'm looking at are 0.062" FR4, RoHS gold immersion, black solder mask, 2 oz copper. Any suggestions with regard to fab choice or specs would, just let me know. Obviously I'm comparing the "standard" options as well, but from what I'm seeing so far, they are pretty much throwing in these "upgrades" due to the volume and new customer status.