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I'm almost comfortable guessing that your problem looks like a bad combination of settings. From dpi to lpi to angle, etc. Have you tried varying them at all?

Make sure your dpi is at least 300. That will leave you a little more room to tweak the lpi and angle. And not get such a 'crunchy' looking effect.

Asides from that though... here jonc, checkout this guy's free plugin for PS. He says it's a PC plugin, but since PS's file format is OS independant, it would stand the reason that the plugins it uses would also be. (although i'm fairly sure i'm wrong on that... i'm just being optimistic)  [honesty]

http://www.geocities.com/murakuma/mmplugins.html

It's a halftone filter with some great setting options. One of which is that it allows you to stay in RGB mode, THEN convert to BMP (optional), without having to use PS's default halftone filter. Plus, it allows you to preview the effect before you apply it. AND... it also has an anti-aliasing option that smooths out the look, it you want. You wouldn't want that though for silk screening; because it producing grey levels. And ontop of all that, it will allow you to use any 2 colours you want to create the effect. It really is a great lil' free plugin.