To do somthing outside I look to ACM first. DiBond is prolly better if it needs to be bent, Polymetal is good except I had some red sheets fade horribly in less than two years. As far as ACM I use all Max Metal from Grimco, its cheap and I've prolly went through 100+ sheets with no problems. I use the 6mm if I need a thicker
sign.
As far as PVC, I have had good success with PVC in certain instances. I've used .25 or .5 inch white pieces to make small
signs, mostly stuff that isnt expected to last for years but it has in many cases. Also I have
signs where I used PVC for letters or other elements that are attached to a
sign of a different material, I've never had a problem with these either. Paint will prolong the PVC life, and the white is the only color that you ever want to put out uncoated.
In a northern climate I belive mounting is the key, in most cases I use PVC in an instance that it can be mounted with a flexible adhesive only. That way it can expand and contract and won't break. What you dont want to do is screw it to a wall or somthing like that, it will crack around the screws.
Also I just found one brand (Excell I belive) that makes a PVC with a really nice high gloss top and bottom, its supposed to be outdoor durable. But I still wouldnt hard mount it.
Thats my experiance in Ohio, SignManiac makes some awesome PVC
signs, but hes in Florida.
Kevin