Thanks! I'm not sure how the design of the 03 housing would change the difficulty level....
As far as picks, I was using ones that were almost straight ends, with 2 knurled sections along the shaft. The smooth handle ones are no good as you need to apply a significant amount of force to work the end back and fourth.
In all honesty though, the next set I do (yes, I've already got something else cooking, for a summer project

) I'm just going to cut open...you could have them open cleanly in 20 mins. Not to mention With the plethora of structural adhesives they have available now and a good butyl seal, there should be nothing to worry about...with the added bonus of being able to keep the skin on my thumb!!!