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I would consider something like Rick's suggestion. Have the while thing routed from HDU, including the grained background.
Leave a flat edge to mount some real wood to. That wood can be stained and sealed with a two part marine clear. I have
mahogany frames that have held up for 10 years with...
My first real sign job was in a city sign shop and we did these in a vacuum applicator with heat.
If it's the same type of blank that has a thicker edge applying by hand will be challenging with that type of material.
How about a show for "Top Sign", like Top Chef or Project Runway? They did for interior designers and now they have one for Steam Punk. For the inaugural competition I would nominate Gino, Old Paint, Bob......
To me it looks a lot thicker than a standard tube frame.
What do the other signs in the plaza look like?
It looks a little thin too be electric but it almost looks like a ACM face screwed over an electric can
I wouldn't even consider intermediate. Either the best cast material or one of the vinyls made specifically for rough surfaces.
But since it had vinyl for 10 years I would assume it was regular cast vinyl.
Actually I have been a copywriter more than a few times for my biggest customer...they'll call up with the "problem" the sign needs to solve, describe what they're thinking about and usually say "You word it how you think it work best"...and I do. Maybe it's because I had a lot of Marketing...
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