Very interesting Iggy. Thanks for sharing your process. I always apply my patterns direct to bare wood with a re-positional adhesive spray and rarely have problems. If you can find a cheap compressor that will save you having to buy expensive cans of air. I find mine useful for all sorts of things and recently picked up a brad nailer for it which is great. Although you don't sand your pieces, I would also recommend a sanding mop in a drill press. You can make one from a long bolt with a couple of nuts and washers and strips of abrasive. It makes quick work of removing fuzzies and softening the edges.
I wish you continued success,
Rob