I just made a 2/3 width dash for my Rover last weekend.
Used the first template posted here (got it from
www.minifinity.com) but really found that having the template was just really a starting point, lots of trimming and angled jigsaw cutting later (to fit flush with the top dash rail), it kind of fits but the air vent is about an inch off despite the dimensions being pretty much bang on as far as i can tell.
Anyway - my experience may not help too much as I assume clubby dashes and air vents are different from mine and i made mine 2/3rd specifically to avoid having to worry about the gauges.
I am also pretty ham-fisted at these things and do not have the best range of tools or a workbench, so no doubt would be easier with a bench and clamps and better power tools!!
Will post some pics as soon as i get them up to my website but I put in my stereo, double cigarette/power sockets, a locking glovebox and cut three holes ready for some 2 inch guages at a later date. I then put a layer of foam and then covered it in vinyl.
As for fixing it to the car - this is the part i am most proud of - I looked at all sorts of bolts and brackets and just couldn't see how best to fit them:
(advice I read said to fix some long bolts thru the dash and attach them to brackets using wing nuts - all very well but i just couldn't see how to fix right-angle brackets anywhere when nothing solid inside the top and bottom of the dash are flat, never mind getting a drill in to drill some holes for fixing them)
I used these devices (can't remember the name of them now - I'm sure someone will know) which I found at Bunnings for about $6 which are used for tensioning cables and wires (think that they might be for boats) with a hook at one end with a reverse-threaded bolt and a loop at the other with a normal bolt, the centre section then just screws and pulls the two bolts together, so without having to drill any difficult holes in my car, I secured the loop end to the back of the dash with a couple of screws and just hunted around down the bottom and up the top of the dash for a solid bit of metal to hook the end on to and then just tightened - holds the dash firm as hell and is dead easy to take on and off with no permanent damage to the car. Note - this will only work if you are going to have a hole big enough to stick your hand through to do the tightening (same goes for the wing nut idea i guess).
I don't know if that makes sense - i'll try to remember to post pics tonight when i get home.
Good Luck however you go, cheers for now...