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I am in NH and install lots of signs. We use a wind load calculator and 4" X 4" posts should be fine as long as the sign isn't to tall and the posts are deep enough.
I have run a one man shop for the last 35 years and LOVE IT! It has taken time to sort out how to make it work but it's not rocket science. First charge enough. Second schedule the work at a reasonable pace. I personally used to work 60-80 hours a week but at this point my motto is work less and...
I recently bought a Shopsabre 4X8 with vacuum but no tool changer for 25k with shipping. It's a very stout fast machine and very easy to run. I am a one man sign shop. Also these guys deal in a lot of used routers. They usually have a couple dozen. https://www.kdcapital.com/used-cnc-routers/
HDU is closed cell foam there for it will not work at all. If you can imagine a block of pingpong balls glued together that's what HDU is like, closed cell.
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