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Futura Display Acct. A. K. Rev. C

Sorry, no. I know they sell something like that for MEK and ABS plastics, but not sure about polystyrene.

Whatever material you are gluing, you are gluing polystyrene so I would use that. It's like adding fiberglass flakes to fiberglass resin to thicken it up.

You could try adding some polystyrene "powder" to the liquid MEK to thicken it up. In a pinch I've used the dust created by cutting material on a table saw to thicken glues.

as suggested, shape the top to increase the size, a little more color to pop the sign...here's a quick rough idea

I have done septic trucks, asphalt tankers, concrete trucks....all with cast vinyl. I know that aren't washing them with baby shampoo and washcloths and most have held up well. Of course I also always give the standard warning about pressure washing and harsh chemicals along with the "no...

The best cast vinyl you can get.

On a separate note...when dealing with jobs like this my CYA warning is at Defcon 1. Especially when it's a job with multiple bureaucrats involved. Make sure every person who is supposed to sign off does and that there are prominent warning about the client being responsible for any spelling...

Wow, good for you. I usually mark up on a sliding scale that also has risk calculated into it.

You want your printers/laminators in the same air as your fabrication area? I would want as much separation as possible.

Sounds like your material and fabrication options are already set, so your finishing methods are OK. Drop the final coat of varnish, that will fail before the paint. My suggestion would be to add a little roof to try to keep the direct sun off it.

I use a stencil company, send them the file and hand it to the client

A mobile sign business where you travel the country and hit up small towns that don't have a convenient sign shop was once viable, but now it seems every podunk place had two sign makers. Just making a home based business mobile doesn't seem to make much sense as for the reasons ams pointed out...

Depends...there are a lot of variables, including the design, but the "eye doesn't lie", well, it does, but if it looks level it is. Sometime there will be a molding or body line that forces you to adjust to it because it makes a "level" layout look off level. We will often have a conference and...

I agree with Fred, at least that's what I would hope it was. Try different foils and brands if you have them.

Do you shade on the left because you are a lefty? I think I recall my sign painting teacher mentioning it was harder for lefties to work over wet lettering.

Does it have to be PVC? Maybe try acrylic from Gemini

For smooth walls I like Phototex

here's one

Yes, like letterman said, as long as it's a "real" paint job you should be fine. There are matte laminates available that can probably get you close, but sometimes it's cool to have a contrast, high gloss lettering on satin/matte finish.