Looking for someone who can make replacement channel letter faces off of tracings

Trace the old faces onto the new plastic and cut with a bandsaw / jigsaw

 

Only way to do it Z Signs.

 

Another way would be to remove the cans double stick tape the plastic to the back of the letter then run a flush trim router around the letter

 

you'll never get it right from a photo, as you only have like a 1/8" tolerance before you're screwed in either direction.
trace letters onto acrylic, drill the inner corners with a 1/8" bit before cutting with jigsaw (else chance having shatter-points where jigsaw lines intersect)
...if you're replacing faces that no longer have the acrylic letters available, then use a piece of coroplast, or better yet the piece of acrylic you intend to use, to span the can and trace.

 

Hand cut. In fact, it's occasionally cheaper to replace a whole set of letters...

 

agreed. We are working with a client on this same thing. We talked them into 1 new can and we are hand-cutting the others based on tracing

 

hand cut - spray mount pattern to plastic & use 2" beaded styrofoam as a cutting board. easily cut 6-10 per hour. file burr off edges. old school is the only way. somebody could spend hours digitizing & not get better results. now if it was multiple sets you could find a large format scanner & put it to use.