Gave up on waiting and decided to plunge in on my own. Found some $5 nunchucks on the internet (tmart.com) and hooked up a AVR controller board (aurdino clone) and programmer.
Working on two versions.
The easy one has an AVR board in a small box with a battery & switching P/S, a connector for the nunchuck, and a CHDK USB remote compatible cable. It uses I2C communication with the Nunchuck and does not require modifing the game controller. Pretty much what rand0m originally suggested here.
The harder one builds everything right into the nunchuck handle including a really small RC lipo 3V battery. No external box to get in the way - just plug the nunchuck into the USB remote jack on your camera (adapter or mod'd cable needed). I'm going to gut the nunchuck electronic and run my ATMEL chip in ultra low-power mode hoping to go months between battery charges.
The stuff in the picture is for the 2nd version. The switches and joystick are wired directly to the AVR board and it communicates with the CHDK's built-in USB remote "zoom" control mode. Works nicely - zooming in & out with the joystick and shooting with the buttons. I just need some more parts to arrive in the mail next week to start the final integration. I'll probably do a custom script rather than use the built-in "zoom" mode> Or maybe I'll add a new controller mode to the USB Remote 2 code! That's what I had in mind when I did the original code for that.
Incidentally, the programmer board has a 2nd serial port that allow the target AVR board to communicate serially with the PC via a USB port. Very handy for debugging or high speed control & feedback from the AVR chip and whatever is wired to it I/O.