How can I apply wooden letters to a metal exterior door without holes
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Construction adhesive.
Loctite PL 375 VOC Heavy Duty Construction Adhesive and Gorilla Super Glue Gel are some good adhesives for attaching metal to wood. Elmer's ProBond Advanced is another adhesive that can be used to attach metal to wood.
Have you tries caulking
https://inspectapedia.com/BestPractices/Exterior_Construction_Adhesives.php
How about putting magnet strips on back of letters. You can get flexible magnet strips at hobby stores. They can be cut to lengths you need.
Glue a magnet to your wooden pieces. Then you can place them anywhere you want. And when, you remove them, there will be no damage to your door. You could use an old business card or advertisement, that has the magnet on the back. People put them on there refrigerators. This material cuts easily with scissors. đŸ˜‡
Also Loctite Stik'N Seal Outdoor Adhesive, and Liquid Nails.
Magnets!