Lol. Your install was definately a little more difficult than mine.
If they aren't the same shape as our seats (I believe they are) then I am going to cut my foam so that the fan can still push the air through them. I am not sure if the 03 seat covers are perforated like the 02 seats, you would probably have to get them perforated.
Sounds like your switch, whenever I first did the passenger seat it didn't work very well (came out of a Navi with no doors) so the switch had gotten wet, replaced the switch and it worked flawlessly.