Joe. as so many others have said, this is awesome.
I will be attempting this at some point. I have an 02 Escape and I think this is doable.
I don't have the factory HU handy as I'm traveling right now, but measuring it won't be of any help for this since the actual chassis of the OEM HU is not DD. The face is, or close to it, but behind the face is a much smaller chassis.
So, I'll have to measure the cavity at some point and make sure the dimensions look good. If not, when I'm ready to get going on this, I'm hoping I can work with you back and forth to come up with a design to work.
Did have a question though. Where'd the volume control go? Maybe I missed it, but I thought you manufactured a volume control out of an old hacked mouse and put it in that panel where you now have the on/off switch and the rs232 connector to modify the lcd settings. I probably missed something in the thread though. 36 pages and I'm sure I probably did.
Thanks again and please don't go anywhere as I definitely want to do this and will surely need your help.