Wow, i have really had my fill of sand paper and primer.
Used an epoxy bumper repair kit from Canadian tire (little white and black tubes, sands great, and $9.95), and rusto-lian primer + flat black from Home Depot (matches the interior ok, but a bit fragile so i added a lot of coats).
I sanded with 200 grit (on a little orbital), then 400/600 (by hand), followed by a very fine steel wool scrub pad, get the smooth uniform feeling.
I wanted to keep a radio as a backup as I move my mac mini between my two cars, so I gutted a a cheap double din kit for the parts to mount the radio, then used tape to mark off the lines and build the border, looks pretty flush.
Thanks to grayvader for the stock picture of the bezel.
His work and my inspiration is here;
http://www.mp3car.com/vbulletin/show...de-empire.html