Personal opinion- Plastisol ink's suck because they are really bad for you and the environment and they crack and you need a crazy junk to remove the ink from your screen and that isn't good to wash down into the sewer. I am not sure what you are trying to do here bbut if you are a $0 budget I would try to work away from plastisol.

here at Cinder Block we use clear gel plastisol for foil. the gel has a smooth surface that makes the foil stick better. "use 85 or 110 mesh", says our production guru (i just asked him).

plastisol is a pain in the ass, and nasty stuff. i'd steer clear of it unless you are doing a lot of printing and have the infrastructure (heat curing, cleaning supplies, disposal means) to deal with it, or if you have to print light colors on dark garments.

i don't know about your plan to paint epoxy over the door screen to make your stencil. sounds like it might work, but you will probably have difficulty getting the paint to close in the holes completely. i say go for it - you have nothing to lose but a little time, and you might discover a new technique or two in the process.