I'm an experienced GIS guy but I have never worked with AI. I have a client that has asked me to supply him with some TIGER road files for use in AI. I'm using Arc 9.2 with maplex and the map he wants covers all of Long Island, NY, with every street showing, and most labelled. His final map will be roughly 8'x5'. He would like other layers such as landmarks, water, etc. and labeled as well.
I have gathered all of the TIGER files and brought them into arc. From what I heard, it's best to dissolve as much as possible, which I have done. I am basically left now with a mxd layout of all of Long Island with the maplex labels locked. I'm not sure where to go from here? I sent him a small sample area and there were some issues:
"the street names are not intact in the Illustrator file; that is they appear as individual letters, not words, and are therefore not scaleable or editable"
How do I resolve this in Arc? Also, is it best to extract each road class into a separate layer, symbolize differently and apply unique font styles/size to the labeling before exporting? I've also heard that it's best to export as EPS?
Any help would be appreciated. I don't have AI so it's difficult for me to test out all the different options. I attached a sample area pdf file for reference.


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