Ok, so I did this two weekends ago, I didn't find a whole lot of information on this so maybe this will help someone. I have a '99 TJ and wanted a place to put more switches that looked factory. I couldn't go with a Spod because I have a Tuffy overhead console. I didn't want to go drilling holes all over the place and make my jeep look tacky. This is actually really easy and will turn out great if you just have a little patience.
Total time with this project without wiring switches: 1-2 Hours
Cost: 4 switch bezel without switches $25
03-06 center bezel without vents $50
OTRATTW switches $15 each
Now, first off, I know you can just go and straight up buy all the parts and swap them out, but that includes tearing down the entire dash which will be an all day job if you haven't done it before.
First start by popping off the defrost vent piece, which can be done by carefully prying it up with either a panel popper, or a flat head screwdriver. After that, remove the screws holding the center piece in with the vents, don't forget the one behind the ash tray.
If you went the route I did, I got the new center bezel without vents, which is fine, it saved me 25$ and they just snap out and snap back in the new one.
Now, On your new 4 switch bezel the only modification you will need to do is sand off the locator pin on the passenger side. now that you have that sanded off you can test fit this piece in your Jeep. Loosely screw the two left screws in place till they just touch the plastic, and begin to draw the bezel up. grab your sharpie, and mark where you will need to clearance the vent duct behind the new 12 volt outlets. which isn't much, but enough to make it not fit.
I grabbed my DeWalt rotary trimmer and made short work out of the dash. keep in mind when you turn your fan on little plastic shavings will fly everywhere, watch your eyes!
Now you will have to plug this back up else you will be cooling the back side of your switches leaving you with no air out the vents. Screw your switch bezel back on again, this time it should sit flush to the dash, drill your two holes on the right. I didn't use speed nuts yet as I don't plan to take these in and out very often, over time I will probably have to add them. Make sure everything lines up. I used a piece of HVAC duct I had lying around, it was easy to work with and bent right to the shape in about 15 minutes of work. I went with a 1/2" overlay then about 3/4" to 1" deep, width will depend on how much you clearanced. Test fit this piece in place, drill two holes for rivets, I used roofing cement (bad idea as it still smells when I turn the heater on two weeks later) Use something odorless to caulk the seams around it and rivet it in place.
Wire your switches, any existing will just snap back into this one. I added some OTRATTW laser etched switches in the blanks that were left after I replaced my factory fog light switch. They were very snug and pushed right in. On that note, OTRATTW's Website states that you should not mount these switches in this location due to light bleed from the top light. All I did was not wire the switches to the running lights as the switches are very bright, and can be a safety hazard at night.
Now the last piece is really easy, grab the new 03-06 center bezel and flip it over, in the middle by the retaining tabs are two locator pins, grind those off and the bezel will now snap into your jeep.
So now for the last fitment issues. The radio in the earlier TJ's was farther back in the dash as you notice in my picture. All I did to fix this was to add longer screws and a 1/4" x 1/2" spacer on each of the longer screws on the radio to bump it out. The temperature dials are just slightly set back as well, I took a paint stirrer trimmed to fit and screwed the climate controls back in and perfect fit.
This is the radio before
I installed 1/2" spacers with longer screws.
This is the radio after
I installed 1/2" spacers with longer screws.
If anyone would like more pictures please let me know and I will do my best to get them as soon as possible.
Yes, I could have install a 03-06 radio adapter to fill the opening, but I want to install a different radio with a different DIN size in the near future, so I haven't changed the adapter yet. The gaps don't let any light shine through, I'm happy with how everything turned out. I could have gone with the two bezel mod, but I decided to go this way as this in my opinion looks cleaner, and will ultimately give me places for seven switches, vs six.