Hrm, well, for the type I would probably – if I couldn’t find a font available that met the requirements of the job I would do it by hand, it really wouldn’t be very difficult.
I would find the most appropriate type face and then go in and manually add and move anchors until I achieved the look I was looking for. It’s always helpful to work out a basic pattern essentially, like for each nick or “rough spot” on the characters use 3 or 5 or however many anchor points you want for the look you’re going for and keep that pattern “uniform,” initially for the sake of saving time and then you can tweak it further once all of your characters are set.
Brushes are also an option because it can be easy to create a shape or text and then apply a stroke using a brush that could give the shapes a rough looking edge.
Turn type into a manipulatable shape, under the Type menu there’s an option to “Create Outlines” and once you’ve done that you can apply a stroke using a brush and really work the shapes until you have something you’re happy with.
I hope some of this helps.