Thanks for the help, it's pretty obvious to me now the opening is just right on mine.
I spent several hours trimming this dash, the light bar opening along with the AC vents.

But in my case the shape is wrong, there's too much material at the bottom of the vent and not enough at the top. The mounting holes for the vent align it, so there is no way to offset it upward to fill the void.

How can they lose the "recipe" from 1 dash to the next?

Really upsetting I'll have to buy more VIN rivets and do this all over again, but as stated, it's going to really annoy me every time I'm driving the car and look over at it.