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I chopped up the original screen casing to get it the right size and then glued it to a dash facia that i bought cheap from a scrap yard. Then I used bumper filler to fill the gaps and smooth it over. Once that's complete the sanding starts, and that takes a long time!! Using fine Wet n' Dry paper and plenty of water you can get a really smooth finish. Then it's a case of painting it. Usually with a filler primer first (then more sanding) and finally with a top coat.
The most important thing is to take your time.
Here's how mine turned out...
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FociMan
Ford Focus Collection
EPIA M10K / 512Kb / Creative Audigy NX USB
8" touchscreen
D-Link USB Radio
USB GPS Mouse
Bluetooth GPRS Web Connection
Centrafuse Beta2 / MapMonkey
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