Really enjoy watching your progress and creativeness Todd - Nice Stuff !
What's the planned finish on the grill shell ? Black chrome, black annodize - or painted ? If paint - wondering if you could do it in fiberglass or something non-metallic. Maybe print out paper cross-sections from your cad - spray glue those to plywood - cut them out and build a buck - then fill the openings with foam, sand/sculpt, add a layer of fiberglass and then bodywork like they do speaker surrounds ? Use that as a casting mold - or make a mold and do the finished part outta glass or carbon. Etc.
Maybe mill a mold outta tooling wax and pull a part directly outta that ?
Hope ya figure out a cost effective solution - that's always the challenge for us guys...
We'll be watching. Best of luck !
Jim
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