patfinn,
What sort of sample file are you looking for? Size, color count, target mesh? I print with index all of the time. It lends itself well to manual printing for the consistancy. While gain is still an issue it isn't as significant as it is with halftone reproduction. The variability of manual printing benefits from that aspect.
Most of my personal prints (that I could freely forward) are set up for eight colors (seven top coats and one underbase) that I printed through 230 mesh at 185 ppi.
When I look to index an image I think carefully about where I want to spend my colors. I often separate individual sections of the image with different color palettes to get the right result. If there is a dominant element like a blend that I really want to look awesome it gets an extra intermediate color to make the transition smooth. Things like drop shadows I often separate individually using just a gray scaled section of the image to get the distribution of the dots to be more pleasing. You can mix indexed and halftone dots in the same image if you want. When I worked with plastisol I avoided layering most of the time as a really soft hand was my goal. But there is no reason to not layer color if you want. It won't be a turn key sep, but those are never all that great even with sim process. It is a matter of ink type and your ability to juggle color sequence and flashes to maximize the mix. Indexing seps from a set palette in one shot is the most limited way to make an indexed sep! I'm happily printing DC inks now with indexed seps and the reduced fibrillation on soft hand prints is making me very happy.
Let me know if you want me to send a file for a small eight color image like the pelican or the larger seven color no underbase foiling design that I have attached. If that is too much for you I recommend starting with basic shapes or typestyles filled with a simple blend. Indexing is a great tool in anyones printing arsenal and any manual printer doing long runs with the need to have them be consistent should try it.
Here are my favorite tuts on indexed seps.
http://www.jimiyo.com/indexseps.htmhttp://www.teedesign.com/Technical_Info.htm