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I would definitely stud mount anything that large. Easiest option would be formed plastic Gemini letters but you could make your own 1” acrylic letters too. Also, possibly HDU Foam if you can paint in-house too. It usually comes down to what the customer is willing to pay for to narrow it down...
We have two of the kala mistrals and I do believe it’s the best laminator out there. That said it’s still a little tricky. One thing to check is that the vinyl is rolled up evenly from your printer’s take up reel. If that roll is perfect you have a much better chance of making it the whole way.
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