Thanks guys. I laid a piece of paper over the top of the dash and roughly traced out what shape I wanted the vents. Cut the paper, then retrimmed repeatedly until I got the size set. I folded the center piece of paper in half to complete the shaping of the template (make sure it is symetric). Once the templates were done, I taped them onto the dash and traced them with permanent marker. Took the templates off, drilled multiple spots just inside the lines as starting points, and used a sharp utility knife to make my cuts. Don't remember, I may have also used a tin snip for part of it. Got my cuts as close as I could, used various files to clean edges and complete the corners. Once everything was pretty smooth, I used 600 or so grit sand paper and wet sanded the edges to get a smooth finish that kept the plastic black (it gets whitish if the plastic isn't smooth enough). I bought a screen guard from Lowes (any home project store), it was just a framed aluminum screen that goes over the bottom half of a screen door to keep feet and knees from breaking through the screen. I laid the templates I'd cut over the screen, and traced out the shapes making the lines ~ 1/2" to 3/4" or so away from the edges of the template, so that the screen piece was larger when set on the inside of the dash. This gives room to secure it with rivets. Once I got the templates cut, checked and rechecked their size, I rolled them into the the same contour that the dash had so they'd fit well. Spraid em with black, let em dry, then laid them in place, drilled holes through the plastic that matched spaces in the screen, and rivited it all together using aluminum rivets and washers on the back side. I reused part of the screen's aluminum fram as a doubler on the backside top of my vent to be sure the screen didn't pull away from the plastic dash when it flexed, but I really don't think that was necessary, just use enough rivets and in the right spots and you should be fine. Then spraid some paint into a cup, and used a Q tip to lightly paint the rivets black so they matched the dash and the vent. That's about it. Took a few hours and seems to work great. I've only run the sled for a few minutes at a time since I installed it but it works, tons of heat pouring out of there!
