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So heres a revised tutorial that is 100%, well 99% correct at least
For custom ai, there are special models that are low poly, or don't take up alot of frames.
-For boeing + MD-8X go to Ai aardvark here (They don't do 777's)
-search "fsp777v3_050701.zip" in avsim for fspainters 777
-search "ai_airbus_complete_120685.zip" for fspainters Airbus series, don't use their A319/20/21
-For A319/20/21 go to Avsim and search under FS2004 AI Aircraft for A319/20/21 and use the Evolve AI basepackages which are all available at avsim, normally you would get them from their website, here but its currently down. They also do the best DC-10 models.
***All repaints are available at avsim, just search for the airline in FS2004 Ai Aircraft, somtimes the base model are included in these packages, but more than often they are not.
Programs you will need to install AI is TTools by lee swordy, also available at avsim.com, search for this "ttools202.zip"
Step 1
If you download a repaint that does not have a model included and is just the paint, follow this step, if it does or you know how to install a repaint skip it and go on to the next step
For this tutorial, we will be installing British Airways A320. Get the repaint at avsim, search ev320ba1.zip. The base model is available also at avsim, search e322cfm9.zip.
ok so when you download a paint, there will be a file called readme, or flitsim, this is nessicary to install the repaint. Open that file up and select everything there, the top should look like
[fltsim.x]//REQUIRES CFM NO_REFL MODEL
title=EvolveAI A320CFM British Airways
sim=evai_a320_cfm
etc
Copy all of that and go to the base model, open up the aircraft.cfgand at the top paste it in. replace the fltsim.x with fltsim.0, as long as there aren't any other fltsims in there, if there are, replace the X with the number of that fltsim in order so if i already had one in there the fltsim would be fltsim.1
once thats done go file save.
now all you have to do is copy the folder named texture.british airways into the A320 model folder and then thats done.
Step 2- Getting the flightplans
Any flightplan you will ever need is in avsim, simple type in the airline and select FS2004-Ai flightplans and search
for the purposes of this tutorial, we will use this one, its not the newest flightplan available, but whatever british_airways_winter_2005-2006.zip
once downloaded put all hte contents into a folder on your desktop, name the folder British Airways AI Flightplans
Open up the file named Aircraft_british airways 2005-2006 if it says choose from a list, select notepad, click always open with and press ok.
AC#2,450,"FSP Airbus A320 British Airways" is one of the lines in side the aircraft file, all you need to do here is replace what is in the quotes with what was in that fltsim.x, specifically, this line
title=EvolveAI A320CFM British Airways <- Select what is underlined here and copy
Paste that over this.
AC#2,450,"FSP Airbus A320 British Airways"
so it looks like this
AC#2,450,"EvolveAI A320CFM British Airways"
then go file save, in the aircraft_British Airways 2005-2006.txt and in the aircraft.cfg file.
move the entire a320 file which should include the repaint and the model into your main fs9 aircraft directory. Then you are done with the plane.
Step 3 - TTools
This step is really simple, open up ttools, go file, user defined source, select the folder you put the flightplans into, press ok. Then all you need to do is click on one of the three things that just appeared, that will highlight all three files and press comple!
Thats all!! Really much simpler than what i said in the other tutorial, i hope i didn't cause too much trouble but thanks for reading and please if there are any issues or comments don't be afraid to ask!
And i hope no one will get annoyed becasue there are now two of my tuts, but only follow this one!!!!!!
Wingletted 733, FINALLY 
I've never encountered this problem
