Well, So I traced the outline of my hatch onto the inside wall of the Nookery. I then measured and traced 1.5" from that mark to allow for fold over. Using my box cutter I cut through the sheets GPW used to line the Nookery and carefully peeled the sheet off the foam. I cut easing clips and then pressed the fabric away from the marks.

I used my Fat Max cutter to cut the smaller wall piece away from the wall. Pretty easy and accurate. I went very slowly and didn't force the blade.

Once the middle was cut away, it was time to make the second set of easing clips and then press the outside fabric away from the excess foam. I measure the outside hole 1.5" from each side and drew lines to guide the cutting.

I placed the hatch frame, sans the door, into the fabric rim from the outside. I then used blue tape to help hold the frame steady and cut the remaining foam away. It took a long time. Again, I went slow and let the blade do it's work. It worked for the most part. I did need to trim things up a bit so the frame would seat with both sidewall fabrics folded in. Here's a shot of the frame in the hole from the inside:

I've decided to glue the inside strips down prior to gluing the entire frame to the Nookery. So I'm waiting for glue to dry and then I'll finish glueing and clamping the frame. Here's a shot of the dry fit from the outside. It is off center of the wall, which was planned. Pretty nice looking.

I also took this little break to trace and cut a piece of 1" foam to fit the internal frame to use to enclose/steady the AC when it is mounted in the wall. I'll brace it with the fiberglass drywall tape I bought. Then I'll cover it with sheets and then paint it to match the interior and exterior. When finished, I'll be able to open the hatch, pop the foam piece into the frame and mount the AC in it. The hatch cover will also be painted to match the interior and and exterior paint jobs, so it isn't quite so obvious.
More to come, stay tuned.
