After many tests for the actual grid playing surface, I've settled on using matte black vinyl stickers.
Alodine / Vinyl sticker: This is the one I've gone with. After graining the aluminum, I had it treated with Alodine, which as I mentioned before is a process that prevents the aluminum from oxidizing. It also gives the sticker a better surface to stick to. Then I had a matte black vinyl sticker cut and applied. This is definitely the closest appearance to the prop, will probably wear better than the other methods, and for all we know, might be exactly the same way the prop was done.
Here it is:
http://www.rebelscum.com/2008/tabletop-vinyl.jpg