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There's no need for a custom made dash as long as you don't want anything too exotic.
Volvo makes "dash frames" that replaces a Volvo head unit with a standard (DIN) sized opening for any aftermarket unit. These are available at least for the S60, new V70 and S80, but I'm pretty sure all models have them. The frame is made of the same plastic that the rest of the centre dash and has exactly the same form than the Volvo radio unit + whatever you have next to it eg. cupholder.
Unfortunately I don't have any pictures of one, but ask your Volvo dealer to show it from the accessories catalog they have for every model.
I'm getting one for my S80. I just haven't yet decided what aftermarket head unit, amp, subwoofer I'm going to get.
-Qube-
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