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Contact these guys.... https://usscfoundation.org/

I'd give an estimate which includes the time to take out the existing faces and bring them to the shop to use as templates..

I wonder if any of the old sign schools had movies? (Like Butera in Boston)

Try the Plotter Doctor. I use my edge every week, outlines on cut vinyl, spot color graphics, decals etc....amazing how much you can do within it's parameters. Right now I'm printing some reflective truck lettering with a black outline and 50 fire dept decals on reflective with transparent foils.

Yep, that's what a dead pixel looks like. That sucks. If you're really not into having a working edge then yes, its a parts machine.

I've run into glass and vehicles that have some kind of silicone sealer/protectorant. We have an assortment of cleaners and I don't know of one that works in every circumastnace, but the auto body prep cleaner is a good one to have available. Then clean with alcohol.

"I have already spoken with Gemini and they do not have this capability"

Yep, run a print test with a solid block of color. Clean head first with only "pure" alcohol. I use wipes made for thermal printers. The edge is a great machine for certain jobs, and it doesn't require any maintenance in between uses, and the foils never go bad.

Yep, the design would dictate how to do it.

Matthews

Yes, hand drawn, we did a lot of that in the 70s. Loved those casual designs where precision didn't count.

I prefer "large" engine turn for most jobs. It looks closest to the hand done size. Small engine turn looks more fake. I've done a few with florentine for a different look.

I have sheeted 4x8s, but at that point just buy a 4x8 print. Or try similar materials from other suppliers as suggested. I wouldn't even discuss the mounting method with them, I would not want to have any responsibility for it. When I do installs like that I prefer slotted angle (thru bolted if...

Overlay the manufacturers logo?

I'd do same as Gino

Start by finding out what is required for licenses. I used to make channel letters and then they required they be UL listed, wasn't worth it.

Doing the job as a sub I would expect the materials/methods to be spelled out ahead of time. For our own clients we assess each job for bets/most economical option. Sometime it's strip/reletter on site, sometimes it's new faces.

Yes, unfortunately there were probably 100s of companies looking to cash in on ADA work back then and most are gone now along with their frames.

We use 1/8" and reverse apply the graphics. The edges are rounded over with a router. We countersink and install with existing screws.

Perfect example of the client isn't always right. A photo mock-up of the sign as viewed from a car may have saved them the cost of a redo. This is a suggestion how to change the existing sign without a complete reprint. Add black vinyl lettering and a panel to cover that useless text