The CAD grille shell is finally ready for some type of CNC process. I haven't decided what that process will be yet. The most elaborate would be to clamp a 6" thick piece of billet in a mill and whittle it down to about 5 pounds - I seriously doubt that's going to happen this time! Too many other things to do to spend that much money on billet, and that much time in front of a mill. The next option is to mill a plug out of wood, wax, or plastic, and have it cast - that's the most feasible plan. A third alternative is to print it in plastic and have it cast. We have a new 3D printer coming that would do a nice job, but it would have to be printed in, maybe four, sections and glued together.
The other problem with 3D printing is the transition between the outer rolled edge and the front panel is supposed to be a subtle concave rolled surface. I left the model as is, to save time, because the ball end mill will automatically leave that surface. If it's printed I need to either create that surface, or fill it in by hand after printing.
The little stand on the bottom is for the emblem. Rather than being perched on top, it's going to "float" in a recessed pocket in the grille.
Some suspension parts and composite supplies arrive Monday and Tuesday, and we get back to work on this puppy.