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Wyld GFI in NJ did some for me that worked well, forget what the material was

NO.

like has been said, you have access from rear so some type backer support will work

We have done a bunch of Fedex truck graphics installs. You'd think they would have it dialed in, but no, the graphics are often not quite, usually because they speced the wrong vehicle. We just make them work, they are more interested in getting it on the road than having perfect graphics.

I used this place for completed signs but they also sell parts https://larklabel.com/lark-parts-sign-accessories/

I just got a generic email, get them every few months I think. Been using them forever, maybe since Spanjer closed, some issues but usually get what I expect.

Unless I have no work lined up I would tell them to have a detail shop do it. It's miserable work, I'd rather letter new trucks

Yep, for pin mounted letters painted them front and back.

I have used PVC for panels or letters on outside signs. Sometimes the exterior grade, sometimes not. Always painted both sides. Haven't noticed any issues. One was a set of address numbers a client needed in a hurry so I cut them painted and stud mounted. They were still looking good 10 years...

Usually flaming them will do the trick, but we use a vinyl made for these plastics.

I think having a EV truck and a shop with solar panels (and maybe battery storage) will be the way to go. But for now it isn't practical since I don't own my shop space and EV trucks are too rare. I did get solar at home last year and may consider a EV car if the production from the panels is...

Thanks for all the replies. I decided I didn't want to get into a big experiment so quoted it using using white gatorfoam and noted if they really wanted to pursue the kraft face option it would cost more. Let's see if they are serious.

Thanks. Hadn't thought of the ink coverage consideration. The client was asking to have a material like corrugated cardboard printed but I didn't think that would work, so I thtought kraft face gator might be closest. .

Can 1" thick kraft face gator board be flat bed printed? THanks

We have used Peachtree and were happy with the product and the sign. We added Gemini letters & installed.

VHB

also interested

We use 20" numbers for the tops of the cruisers we do

Yea, what's the point? It must be your fence so why not just replace that section with the sign and add fencing to the bottom?

We'd trace it onto the new acrylic cover sheet and cut with a jigsaw. Like Brad said, get some cheap thick insulation foam board to cut on, makes it easier. We used to do these on a bandsaw, remember one place that had the deepest throat bandsaw I ever saw, they could do 6' letters.