I have it working. Use M22k's modified version, located in that thread Canon posted. Also Canon, the unified team project is still a work in progress, but is almost complete now:
http://forums.kc-mm.com/index.php?topic=59782.0
I found that some pcs files can not be uncompressed with brawlbox. Definitely make sure that your pac files are bigger than it's corresponding pcs file.
0x80455460 804551E8 Mario
0x80455470 804551F8 DK
0x80455480 80455208 Link
0x80455490 80455218 Samus
0x804554A0 80455228 ZeroSuit Samus
0x804554B0 80455238 Yoshi
0x804554C0 80455248 Kirby
0x804554D0 80455258 Fox
0x804554E0 80455268 Pikachu
0x804554F0 80455274 Luigi
0x80455500 80455284 Captain Falcon
0x80455510 80455294 Ness
0x80455520 804552A4 Bowser
0x80455530 804552B4 Peach
0x80455540 804552C4 Zelda
0x80455550 804552D4 Sheik
0x80455560 804552E4 Ice Climbers
0x80455570 804552F4 Marth
0x80455580 80455304 G&W
0x80455590 80455314 Falco
0x804555A0 80455324 Ganondorf
0x804555B0 80455334 Wario
0x804555C0 80455350 MetaKnight
0x804555D0 80455360 Pit
0x804555E0 80455370 Olimar
0x804555F0 80455380 Lucas
0x80455600 80455390 Diddy
0x80455610 804553A0 Pokemon Trainer
0x80455620 804553AC Charizard
0x80455630 804553B8 Squirtle
0x80455640 804553C4 Ivysaur
0x80455650 804553D0 Dedede
0x80455660 804553E0 Lucario
0x80455670 804553EC Ike
0x80455680 804553FC ROB
0x80455690 8045540C Jigglypuff
0x804556A0 80455418 ToonLink
0x804556B0 80455428 Wolf
0x804556C0 80455438 Snake
0x804556D0 80455448 Sonic
And lastly, I highly recommend that you trim your list of character offsets (seen above), in order to save yourself from filling empty slots for characters you don't use.
(If someone could tell me how to make that list collapse-able, that would be great)
EDIT!!
OH I forgot. If you have ANY gaps for a character's extra slots, simply cycling through that character's portraits on the css will cause the game to freeze after trying to start a match.