The screen I'm using is an 8" Lilliput. This will just barely fit into the area where the head unit was. I was not going to be able to use a kit to mount the screen so I needed to fabricate the faceplate to accommodate it. I picked up another faceplate from my local Ford dealer for about $60 so I could work on it without having my stock one out.
My idea was to integrate the screen bezel from the Lilliput into the faceplate. To do this I had to get the Dremel out and do some cutting on both parts.
The faceplate needed the area where the head unit went to be slightly taller and wider to accommodate the screen bezel. I used the bezel to mark the areas where I needed to cut.
The screen bezel needed to be cut shorter so I removed the area where the buttons are. I can relocate this elsewhere in the car.
I also cut the back bezel of the screen to match height of the front. This way I could just screw the parts back together when the screen is inside the faceplate. You will need to shave some of the sides of the back bezel so it will fit between the metal supports when it is installed. I went right up to where the screws were.
The screen bezel now can fit inside the area I expanded in the faceplate. I then did the following steps:
Using some glue I fixed the two pieces together
Filled the gaps with some Epoxy plastic
Sanded the gaps with 200 grit
Added some filler bondo to finish up some of the rough spots
Tape off the sides where the faceplate is not seen when installed
Sanded everything with 400 grit
Paint with grey filler primer
wet sand with 400, prime again and wet sand with 800
Final coat was SEM interior satin black
Make sure the areas where the top buttons for info/reset/etc do not get too much paint build up so they stick. Sand these areas between coats.
If I was to do this again I would have made the following changes:
Roll the Epoxy plastic into long strips to fill in the gaps.
The bondo is not as flexible as the plastic and it came up a bit.
I would have used the Epoxy again to finish or found something else than the bondo.