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Whatever you decide you're going to charge, I would recommend establishing a Shop Minimum. My shop minimum is $87.50. Only you can figure out what yours should be.
Any cast vinyl will work. We use a lot of Avery cast in the shop, but for working down on the docks I like the cast 3M stuff on the plastic backer. It's not a fatal error if it gets water on it, like when you fall off the swimgrid....
You could just charge a standard "File Transfer Fee". It takes Time to dig up logos, convert to pdf or jpg or whatever and create an email with the attachments. Charge $35 or whatever you need to cover your time and make the process profitable. Spending time to send them something they cant use...
I think we get it from Grimco. I cut a 4' piece into a hand full of smaller sizes. To hold the feltish material I used banner tape on some and 3m spray adhesive on others.
I make my own version of a big squeegie from the aluminum extrusion we get for making road signs. I glue some soft material to the edge. It works amazingly well for large graphics.
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