Thanks guys. I'm just having way too much fun with this. VERY gratifying to finally be producing parts. Lot of ideas in my head almost within reach now.
For the machinist...found my glitch that had the T, R and N buggered up. VisualMill has a ramp-in and ramp-out feature for pocket milling (guess it saves wear and tear on end mills vs. plunging). Would seem they have a bug in the program because it was ramping in (or out, not sure which) and clipping the edge off some of the letters. I changed to 90 deg ramp angle (basically vertical plunge) and nice clean lines now! Job ran a good bit faster w/ out the ramping too. Pic below.
Izzy - I cranked out a couple of the bottom grill after work. Hand worked stuff was pretty repeatable so looking good for making at least a small batch of these.
