The size of the denoms could be okay if the font was different. The one you use has way too much variation in thickness and there's some very thin lines because of it. If you can find a more balanced font it might work at that size.
My 5c regarding colors/spots --
The red one definitely looks best to me of all the color combos you've used. Be aware however that the red as well as the charcoal are a lot darker in person than on screen. Putting my color samples together, it looks kind of dark all in all. The red-gray combo looks great, but the charcoal pulls it down imo.
Green chip: Colors work well together. DG peach is a lot more saturated in person than on screen. The combination can still work but do check out DG arc yellow as a potential alternative if you have color sample chips (which you should!)
Black chip: Not a fan of using very saturated red-ish and blue together. Too much visual chaos imo.
Purple chip: Think this color combo is a classic one from Paulson... nonetheless not a fan of it.