jerryho said:
.... Do you want to give me the instructions now so I can start prepping the console? ...
First step is to remove all the foil from the top half of the console - easiest way is just to peel it: find an edge at the sides (not the face) and then just start peeling. You may need to help it a little to start with an exacto knife, just don't cut into the surface of the plastic! You want to stop on the two sides by the ash-tray - it's easy to make a transition there and feather the edges of the foil and not really noticable as it is only a very narrow strip.
If there are any stubborn areas, you can sand them - be sure to use a block so you are only removing foil, not plastic!
If your console is absolutely pristine and it would be a shame to strip it (rare on older cars - they are typically already bubbling or peeling), I have a spare that already has the top half stripped that I could swap you.
Reason it needs to be stripped of the foil is that you cannot bond to the foil & get a clean finish (at least in my experience). Once you start to cut around the slot, foil is going to want to lift anyway. It is difficult to get a good transition on the area around the Head and A/C slot, so better IMO to take the whole top half off and only deal with a very small transition by the ashtray.
Next steps will be to cut a rough hole then fill it back in again with a glass reinforced bondo so you have a completely filled surface, then sand it completely planar (be sure to use a block!) on the front & back sides. The top should of course be planar to the OEM surface. You're going to want the bondo to be ~ 1/4" thick to give you a nice edge profile.
The finish on the back is obviously less critical, just get it roughly the same thickness & generally flat. On the top-side, you will want to refill any low spots or holes you find as you sand it - this time use a finer grade of filler, like Bondo Ultimate. Multiple sandings with a block are the key here, with progressively finer grits to get a good clean face - this step, in addition to the final cut of course, is what is going to make your job look good or average! Don't worry too much about the area in the middle that is going to be cut anyway, just focus on ~ 1/2" in from where your new slot will be.
Then it will be ready to cut the final hole, for which we will use the supplied surround as a template.
You're also going to want to take apart your vent assembly, so you can paint the frame along with the console & leave the actual grilles untouched. That can wait till final stages of course.
When you install the head, you're going to want to have a little adjustment on the bracket so you can align it perfectly with the slot to ensure smooth operation.
