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My first guess would be not enough heat, or a problem with the vinyl. When did the problem start? Are you using roland ink and cleaning fluid?

It's called Webermade tape tool, but a home made version like the one above is just as good.

Gorilla tape

"Feit Electric" corncobs seem reliable.

run "cleanmgr.exe" from the start menu and delete thumbnails. Not sure if that would help

My PPG book doesn't list duronodic bronze, but using my best judgement I'd say phantom mist ppg1002-7 would be a close match. or black elegance ppg1004-7

You keep posting the same pics and Epson told you that your file looks like that when they print it too? What about printing something else? Same problem? Try a generic non-3m profile?

You should import your car from China too. I bet it would be cheaper than some name brand vehicle. Why have Roland printers when you can get a chinese one for half the price?

You need to hinge it horizontally, and make the vinyl a couple inches bigger than the window. Then trim the excess with a xacto knife after it's on the glass

Hinge it down the center and use a big squeegee

If you drill a hole in the acrylic, you should be able to screw a threaded stud into it without actually using a tap tool.

Those LED rope lights you got could melt / catch fire if you're using them outside.

1/2" thick letters will not look "3D". It will look like flat lettering, as if you just printed it anyway, unless you're standing only a few feet away. If they want dimensional looking letters they need to be 1.5" thick or more. Other than that, If you do this, I recommend studs and nuts on...

I've done quite a few, up to 10' channel letter faces tracing a photo with a $20 camera. And they fit perfectly fine.

No those digitizer pens require a tablet to determine pen location. Your best option may be to photograph the sign and trace on screen.

Top one: 2 installers all day $1400 labor plus what the decal cost Bottom one with 2 installers?: $450 labor plus decal cost

Call Walker Supply. They might be able to, or help you find someone that can. https://www.walkersupply.com/

IDK if superglue would be a good idea. I've used liquid nails "FUZE IT" on large pvc sheets that worked great

Hard to say. Maybe try this program. http://www.pro-lite.com/wp-content/uploads/2019/04/MarqueeLiteSoftware.v1.0.zip