Rob,
I think in the end you will be so much happier with a painted DS versus a printed sticker DS. You know that is how they did it in '76. There is no way for them to have printed these patterns out so good back then.
Also think about this, as it may re-fuel your passion for this. You are the ONLY person who has tackled this project, therefore you will be THE only person with an accurate studi scale DS. People will be coming to you for info and admiration on this project. Much like Guy's Taun-Taun project, if he cheaped out in anyway, people wouldn't be as impressed with the final result as they are. This may take another year to complete but if you take the painting route and take your time you will have one of the most unobtainable prop/models out there.
As I have said, I would be willing to commit a couple of Saturdays to get through the masking and painting.
My rant is over...
Brad