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I will forgo the bah blah blah about the quality of that sign and what should be done. Like Studio 440 said, treat it like any other outdoor wood repaint job. The garden sprayer is a good idea for washing and rinsing. I'd throw some wood restorer/hardener on the rotted spots. Finding a good red...
One of my considerations on projects like that, where I buy a big ticket product wholesale, is the risk I am assuming if something goes wrong. The customer will hold me responsible for any problems, and dealing with a remote supplier that may or may not respond quickly can cause a lot of headaches.
23k loose leaf gold. Never seal gold leaf except on vehicles and glass. I also leaf a little sooner that I used to. I found that waiting till it's really dry will give a brilliant gild, but that also makes it harder to read, and risks losing the window of tack and having holidays.
The original posts were aluminum, and we just repainted them. The PVC caps were dinged up so we replaced them. If I made it today I'd use the aluminum again.
Acrylic polyurethane or any good quality oil base enamel. But in this world it's good to find a quality waterborne paint since we soon won't be able to get anything else. Oh and "cheap paints" isn't a good brand.
I do 4x8s on 4X4 posts with a bag of crete in each hole and never had a problem. 6x6 with crete is going nowhere. When I first started the guy I worked for never used concrete for jobs like that, 36" deep holes and compact the hell out of the fill (which always had rocks), concrete is easier...
Walnut is not a good material for an outside sign. I have made many wood signs over the years and have had good luck making them last with 2 part marine varnish, but it is still risky. Also, what's the point of using a material like this for an exterior sign that has to be legible from 30 feet...
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