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maybe 1/8" thick polycarbonate for your grill block? Flexible enough, pretty indestrucable and virtually scratch proof. That way you can get a pretty fluid fit and finish against the body as well.
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"The test of the machine is the satisfaction it gives you. There isn't any other test. If the machine produces tranquility it's right. If it disturbs you it's wrong until either the machine or your mind is changed." Robert M Pirsig.
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