2000 Chevrolet Silverado Double Din Conversion how to article
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Details: 2000 Chevy Silverado LS
1.5 din stock stereo
1998 Pioneer DEH-P6000
OmniFi by Rockford Fosgate DMP-1 20gb hard drive based MP3 player
from 1.5 din....
....to double din
I used a rotary tool with extension  along with a couple different sized barrel sanders and a cutoff disc.  I used aluminum tape for the backing to support the filler while it cured.
I first modified the stock Metra kit by relocating the side brackets and cutting the top out.  I used a soldering iron to bond the abs plastic together.  It has the pencil type tip.  I placed the iron in the joint and melted the plastic together making sure to melt equally into both pieces of abs.  It still used the stock slide in and lock system.  I then had to extend the sides up and add a top.
Fitting the 2 dins in the bracket
To get the correct measurements on where to take away material I locked the radio setup into the dash and marked with a scribe.  I grinded the bezel with a barrel sander on the rotary tool to achieve the proper height and width.
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