Surface Finishing.
The body filler went on uniformly but sanded unevenly. The ABS slurry went on in globs but sanded well. In the end, I think the ABS slurry technique was the most successful. Also, the glue version chemically welds pieces of ABS together and is far superior to other joinery chemicals, compounds, and techniques.

The results are pretty fantastic. For example, I had to print each of these panels in two pieces to fit on my Bambu labs P1P printer, but post-processing you can’t see the seam at all.
Painting.
Early on I got locked into using Rust-Oleum Painter’s Touch 2X Ultra Cover Spray Paint, supposedly both paint and primer. This stuff actually eats away at ABS. In a side-by-side comparison you can see how the premium build plate texture has been chemically defaced.

As a result, each piece needed about 8 rounds of painting and sanding to achieve decent results. If I had to do it over again I’d find a more suitable paint for plastics.
Assembly.
A whole lot of time went into thinking about how to best assemble the case. It’s engineered to use many tiny screws. The tiny screw heads strip immediately, making their installation more or less permanent without adding any actual structural integrity. So I spent a lot of time extracting the tiny screws and then instead glued the front, bottom and sides together. Screwing the top into place wasn’t an option but neither was gluing it since doing so would entombed the marquee header. I wanted everything to completely disassemble in the event of needed repairs. So I modded the existing header to accept Ikea-like Cam locks. It worked but didn’t cinch tight enough so I modified the model in CAD, printed it again, and the results were excellent!

More later!