Well, I jumped in and started the install. This is going to be a sort of stretched out project, as I don't have a lot of free time for my car right now. However, I've got the unit sitting int he dash and wired up, but it's a serious work in process right now.
I did see all of the pictures of double din (or two single dins, as a few were). I'm actually not going to end up using an install kit at all. Also, I'll keep this first thread up to date with any progress....but here's what I've done for now.
First thing I did was get the old kit out and take a look at the actual hole. There were two lips on the top and the bottom that had to get dremelled off. After that I did a quick test fit...it was still nowhere near the right size. The flasher switch hangs down too far to allow the D3 to slide in. The next step was to take the trim piece off and get the switch out to try and trim it down. This picture shows the panel off and you can also see what was dremelled away.
The flasher switch is held in by two phillips screws. Here's the switch itself. The top piece of plastic is what has to go. Here's the before/after dremel shots.
Center panel back in. All in all, there wasn't much dremel work required to get the whole big enough. The 1.8 DIN hole is just barely too small to fit the D3, and probably most other doube dins.
You can see it's a snug fit. After a few more test fits and more dremelling (especially in the corners) it finally fits (height wise). Here's a few shots of it as is.
The plan from here is to get the nav-traffic box mounted in the glove box, along with the iPod cable. Then the GPS/nav-traffic antennas need to be hidden somewhere. As for the gaps on the side (because I know it looks ehhhhh for now), I'm going to try to get a trim ring for it. I know Pioneer has one that is flexible enough to contour to the dash and hopefully cover the holes. If I'm not happy with how that looks, I plan to create two Bondo'd strips where the holes are, sand the whole panel and paint it all. Also, as for mounting (right now it's just hanging there), I was talking to an installer at work, and he suggested getting some strips of metal, bending it to hit the side mounting hole on the D3 and then the other side mounted to the dash support. I was going to do one on each side, and then something holding the back up as well.
I don't know when I'll get the time to go at this again, but I think it should turn out pretty clean when it's done.