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Vinyl will stick vinyl awnings. It won't stick to most other types of awnings and maybe that's what they thought you had.

Looks like one of those foam substrates that Grimco sells. They have a whole page of them. They are like that Sky Board Jean mentioned.

These folks have replaced Grimco as my preferred supplier...Hall Signs | Custom Signs, Sign Materials & Hardware

I agree with a faux finish to mimic a stain

Yep, how bad is it? Would a full cover print hide the damage? And the higher it is the better. But you may just have to replace.

Wow, that would be expensive...there was a company here that did the traffic signs like that years ago but they're gone.

Wow...new? I could never buy new, it would drive me crazy worrying about the inevitable dings and scratches.

Yep, at least the one we had. I want to be able to fit 4x8s no problem so a full size bed is perfect. And with some supports larger sheets can be accommodated too .We can set up so we can put a "shelf" in the back, lay full 4x8s on it and put the digging tools under. Then you have the rack to...

Not ours. They are mounted on top of the side rails and fit between the rack supports. I'm 5'9" and reach everything easily. My first set were steel, I replaced them with a pair of used diamond plate aluminum ones. I worked with a service body at one shop, the narrow bed was pain.

Actually if you have any painting skill a washed out aged look is easier than a crisp new finish.

F150 4x4 Extended cab, 8' bed. 8' toolboxes on either side and full ladder rack. Never liked vans because so many thing won't fit and getting ladders on and off can be a pain. We also have a mini van though for small jobs and errands. We rent a towable lift when needed.

8 years ago I hemmed all edges, still do.

Yep, I'm with the "they supply it as an artwork" file faction. Even small discrepancies can make a big difference. Back when I did it all by hand a Chinese restaurant had me lettering their doors. The manager wrote on a napkin the symbols he wanted and I used that as my reference. In turning pen...

The only part that seems out of place for a scam is the current client referring them, I would call them

If it's the paint they should return the car because it's defective.

You don't say what kind of project, but a good cast vinyl (and laminate if needed) should be fine. Installing in the cold is a problem no matter what you use. It's best to let it warm up a bit, or warm it before applying.

I don't charge for them. Most estimates aren't that involved, if I get an complicated one I make a judgement call on whether I want to take a shot at it. The ones I usually pass on are for a contractor (who isn't a repeat customer) who is bidding a large project and there on signs involved...

Just to cover their butt. Easier to send them to everyone than figure who should really get them.

One problem for anyone new is you may take twice as long to do a job as an experienced person. So if you use an hourly rate that is comparable to other shops you may never get a job. You may have to accept making less, maybe significantly less, on a job till you've learned the ropes.

"How would the client know which way is the best?" Because you said "Highway Signs" which to most of us means the signs are for a government entity and have very clear specs.