I have been sanding endlessly, while doing that I had an idea for a way to construct my speaker grills that I am testing now. Basically I printed a frame for the speaker grill and then my idea is to soak the bottom of the grill in acetone to start to dissolve the ABS. I will then press the grill material into the abs while the ABS is soft. After it hardens I will trim the metal mesh around the frame, sand any sharp edges and ready it for paint.
Below are pictures of my small scale test that I am doing right now. (Fingers crossed)
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