I need advice on finishing a 3D printed Babylon 5 PPG

I use Rustoleum 2 in 1 filler and sandable primer. It works great on 3D printed items. I wet sand after 2 or 3 coats. I prime again after that as needed.

I use 220 up to 400 grit wet sandpaper to smooth out layer lines and imperfections.

You're also going to want to pick up a set of needle files. They can save the day for smoothing layer lines out of tight corners where the sand paper can't get into.

For silver, particularly aluminum, I use Rustoleum Imagine silver. In 1 or 2 coats you have a very convincing metal surface. I have only ever found it at Target. I order it from their website now as I live far away from a Target store. But they have always had it in stock.

Once it's cured it can be handled without any dulling.
 

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4mm of polystyrene sheet seems to do the trick. Once the 'fin to body' outline is defined at the top of the grip, the only remaining work should be refining edges, gluing grip panels to the fin... then epoxying the hell out of the grip/body interface. And painting some metallic on the outside edge. Sadly, the 4mm spacer is too thick to re-use the bolt and nut combo that originally came with the grip.
ppg-poly-fin.jpg

(or bits from two 2mm sheet, roughed and super-glued together. When it's what you have...)
ppg-draw.jpg

And voila
ppg-grip-spacer.jpg
 
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