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What does the town require for permits?

There's a Gerber Facebook page which may help.

We double sided HDU same way, two 1" faces and usually a matching panel of ACM fpr the middle of the sandwich. We use a polyurethane adhesive and a few screws if possible. You can also build in the mounting hardware when putting the panels together.

Yep, buy them paint white or light grey and apply white reflective.

This seems like perfect application for a 3D printer

I usually spec stainless steel when going into something tough. And if it's in a place people can grab it add some construction adhesive instead of silicone

If it's good shape otherwise, I'd wipe lightly with an old scotchbride pad, clean and final wipe with alcohol and repaint. 1 Shot isn't what it was, and red is one of the worst.

We do this on all RealGold truck lettering. Apply clear cast vinyl with an extra 1/8" or so trap. We Edge print the black but the technique is the same for layer lettering. It can be done prior to install on the roll but it's much easier to do on the substrate

Convex works.

I like to warm it a bit, carefully. Then a razor and some juce

These are always more work than they look, if you want to do it right. Can easily cost almost as as much as a new one

If I was in your shoes, getting a decent paycheck with good benefits and time off Id' start doing side jobs to bolster my bank account and options.

justbraillesigns.com

I've done several of the painted faux finish posts. Not too hard and looks pretty good. Another option depending on the size of the post is wrap with Trex

We go over it with some polish compound, and wax after it's lettered. Any more work that it's not worth it.

It is a political sign, therefore protected speech, which a lot of times exempts you from zoning, but taht is debatable. In any case I would still think it would requite a building permt to be sure it's installed up to code.

Search "icons" for those messages, there will be symbols for Propane, No Smoking and Danger

We have towns that require a stamped drawing for a 1x8 dibond wall sign..permits cost way more than the sign.

Like Gino we've used many things, usually coro because they want them as cheap as possible. But PVC if the want a smooth finish

You could upsell with a copper "roof"