Try this:
- Make a dedicated layer for the sheet number and make that layer use color 255 (see image-1).
- To plot, use AutoCAD PDF (General Documentation).pc3 (see image-2 and notice PDF options maintain default)
- Execute the plot.
1-Use a dedicated layer with color 255.
2-To plot, use AutoCAD PDF (General Documentation).pc3
If you wish, you may right click PLAN tab and go to 'Page Setup Manager'=>Modify=>check the box 'Display Plot Styles' because doing so will make the layout environment to look like the finished product you would get when plotting with your VARA_full-size.ctb (see image3).
3-From Page Setup Manager, check 'Display plot styles' to make your layout have the appearance as though you are using VARA_full-size.
If you don't check 'Display plot styles' in the Page Setup Manager, then your layout will be in color (your final print will maintain VARA_full-size.ctb and, of course, still plot to black and white).
Attached is the final plot job using General Documentation pc3 with the VARA_full-size.ctb
The reason you want to use AutoCAD PDF (Gen Doc).pc3 is due to 'pre-processing' that AutoCAD uses in the various pc.3 files. Your old plot configuration (according to your screencast in the original post) used plot.pc3 and whatever that is I don't know , but it's not giving you the correct results. You are over-thinking the possible causes, e.g. PDF merge control (Lines Overwrite) and all that jazz, when the issue is simply choosing the correct pc3 file with a dedicated layer to control the color.
Chicagolooper
