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Like was said, clean the sprockets, I use some alcohol and then a bic pen with the nib/ink tube taken out to finish around the sprockets. Give the rest of it a food general cleaning. You should find it with google If the rollers are really chewed up you may need to replace them. For large easy...

Yes, there should be holes where the set screws are located. Once you back those out the whole face comes off

As was said, cast translucent using application fluid. A white border is common, especially with blue, to make them more legible when lit. New faces would be even better.

I understand it from clients that aren't designers, but when professional designers send stuff that's not to scale....

Looks great John. I like the gravel bed around the sign, the landscapers can't whack it

cheapest double stick tape

Just had a customer (liquor store) ask for a quote for coro yard signs, told him his best price is at 10 pcs dbl sided and gave him the number. Then he dropped off the text, each has 10-12 lines of items with prices and he wants to add pics, and there are 4 different designs...."No thanks...

I buy these wholesale, makes no sense to do in house

I also tell them to just purchase them online, cheaper than I can do them. But when I've had to do them for one reason or another I find the closest image I can online and make it work.

I never liked clear acrylic rails outside because it always ends of dirty looking.

What T. Nichols said. If you have a lot of the poly just put it on both sides with bolts in the open spaces and pinch it tight

Depends.

We have added scrap pieces of 6mm ACM around the perimeter.

since all the nuts on the back will keep it from being flush? Depends, if there are lots of nuts, just trim the bolt flush, it'll lay flat. If there aren't many use 1/4" stock and countersink

We use whatever we have in the cut offs bin, aluminum, ACM, flat stock. Paint to match wall.

"but what if I need to get a pantone match?" I've used this place with great results. https://www.myperfectcolor.com/ One job was a bunch of acrylic letters with about 5 or 6 PMS matches, came out great and lasted really well.

Steam is an option or what we usually do, heat and fingers.....

Matthews

We use 3M 2080 white gloss color wrap for something like this. Like was mentioned, I would discuss skipping the more difficult sections to save time ($). It's a commercial truck and if it's mostly white some raw metal will look fine. Important to clean well before install. I don't have a set...

Why remove? Can't you go over the existing wrap with removable film?