I have figured out what is giving me problems on the gun sights.

During the EDM process I was not flushing enough and some debris drifted to the lowest part of the mold and became fused there. This is unfortunately the gun sights which are the defining characteristic of the front of this car. This debris prevented the plastic from filling out the cavity and created the fuzziness.
I always check with clay pressed in to a cavity to see how things are looking and they looked great. But I checked before the EDM process. I really was not aware of the problem until I started trying to paint them and got strange results. Part of the problem is my decreasing eyesight with tiny things as I age. :oops:
The mold will be cleaned up and I will try to make a new batch when I get the time. I have stopped selling the car for now, although if you are going to build a race version that grill is fine.
Once the mold is fixed I will re-post and we can get better gun sights out to the guys building street cars.