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You would either need to trace the face on cardboard or paper, or take the face back with you. You shouldn't need to take the whole sign down, but that's up to you depending on how comfortable you are with making a new face and having it fitting properly. It should be pretty easy to re-design...
Send the print as the actual size in Flexi. Flexi operates in inches. Your design should be set to 48"H x 144"W in Flexi (ignore document size, it means nothing for sending to RIP). No idea what you mean by converting it to letter size. Post a screenshot of the problem.
If you don't do painting, tell them you don't do painting. Offer to replace with some better vinyl that is made specifically to stick to a block wall. Briteline MultiGRIP or something.
I wasn't really suggesting anything, besides how long I think it would take you with the info you gave. If it's too much to deal with using what's available to you, why not just sub them out to a wholesale printer?
Your network ip of 75.xxx is the one connected to the modem for the internet. Since you have 2 network cards make sure you're changing the correct one. Subnet should automatically fill itself in when you click on it, it's probably going to be set to 255.255.0.0. Make Your IP and gateway and...
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