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I know of the Zoo-Dad, but today while doing the front 05 conversion I decided to drill hole on this side of the grille. The usual place where everyone drills has a cover to force the air into the condensor. And since the Excusrion has 2 A/C's I wanted to insure all the air continues to route directly there.
I did a similar project once for a Western Diesel kit on a customers truck. I think I removed alot more of the bulk head than that, so you should be good to keep cutting.
An intresting trick I use alot on plastic, that makes that and bedliner modification easy, is to put a roto-zip bit in a drimel with a flex shaft. It makes a mess, but it cuts through the plastic with ease and is very controllable.