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Photos are worth a thousand words, I would also expect replacement

Some white acrylic chaulk to fill the voids

From the Gemini catalog Finish Notes: All Patinas, by their very nature, will vary from letter to letter and order to order. These finishes will change in appearance over time depending on contact with moisture and temperature. Patinas can “bleed” onto the installation surface when installed...

They can't make a pattern once the letters are shipped, a PITA to do it yourself, but not the end of the world. Like was said, are you sure it was on your order confirmation? As for the patina, photos would help to see how bad it is. I've always been pretty satisfied with Gemini.

Maybe Triplet & Souvenir

Serpentine & Windsor?

With 30" letters I would do combo/all and lots of silicone on stucco

I used to use a similar font when hand lettering, the old timers called it "Stovepipe" You could layout the whole thing using the width of a ruler or yardstick.

I never liked the way a sign looks screwed flat to a sloped mansard roof. We make a couple triangles from slotted steel and paint them the same color as the roof. These are bolted to the roof, thru bolts if possible, if not solidly screwed into whatever the studs are, and sometimes if there is a...

:help

Unless the faces are almost new, replace

Why a new sign? Is the name changing? The old one doesn't look that bad in the photo (at least the material doesn't look bad). If it has to be replaced a carved sign should be the first suggestion. If budget isn't there then at least a thick sign so it doesn't look cheap. I would probably do a...

I like the idea.

Are you going to have an industrial look with big visible hardware for the standoffs?

What you use for the graphics depends on the design. Whenever possible I use cut translucent vinyl. If you have to go for a digital print you need a double layer "day/night" print for best results.

or make it 24"

Yes, it a banner type material and some versions are backlit. The main point is it's a large "banner" that can be installed stretched on a frame, eliminating the need for panels.

Some kind of seam is inevitable, especially outside. The only way around I can think of is a flex face.

Those decals that last longer may not be inkjet. You want them to last longer you'll have to laminate.

Are you asking about what to hang the sign from the arm with, or what to attache the arm to the building with? I see a detail for using chain, I prefer a solid strap. And as has been said, a internal or external frame or some form of continuous support is needed. Thru bolting to the wall is...