Around 5 feet wide.
Oh dear. This will at least be an easy one to learn on. Call your distributor, order some trimcap, I like channelbond typically but the guys have been using weldon, at any rate you'll need glue. Also a big fan of poly over acrylic for these, polycarbonate can take a beating, acrylic stays white, pick your need based on that. Remove the old face, trace onto new polycarbonate face down with a sharpie (poly has a back side, make sure you put face down on the back, cut right on the line, decorate, then trimcap. Easiest (cheapest?) way is to get a piece of plywood, put 4 nails down to hold it in place. then start putting the trimcap to the edge, adding nails every 1" or so to hold it tight to the plastic, trace with channelbond, allow time to dry, 15 minutes or so, and do 3 coats. Carefully remove the nails after a couple hours, slip it over the can, add new screws in totally different places.
Never had a problem, except when channelbond got hit with additional hazmat shipping, and it was all stuck at the warehouse until they got an exemption or found a courier, no clue how that shook out. Though I'd avoid getting channel bond on vinyl, it will blister it pretty bad.
Yeah, what's the wow? That a seemingly simple face replacement has become somewhat complicated? (at least for my small shop) I'm open to trying new things but this is sounding like a PITA.
I'd wager you could holler at signfab and have them produce a face, but it will be exactly the shape you send to them, so it would be best to pen a pattern that is close enough that dropping the face over it matches precisely. Only problem for them would be shipping economically. Though based off the snazzy looking roof and beams, I'd price it high and tell them a new rectangular cabinet wouldn't be too much more expensive in the end.
If it's only 64"x30" it's small as I suspected. It's likely acrylic. No need for the disadvantages of polycarb on a small face like that. The trimcap isn't all that expensive. A 150' roll ranges from $60-80 depending on brand and color for 1" wide. 2" wide is about $110. You can get it from Glantz or any supplier that sells things for electric signs. They sell the cement you need as well. You can also buy 10' lengths for about $5. You'll have tons of it left over on the roll, but you can charge the customer for the whole roll.
