Remember to modify kexts' info.plist OSBundle Required property to Root if needed (Voodoo PS2needs this, for instance).
The "Root" value seems to be required for any kext to load successfully from /Extra/Extensions.
It involves using Chameleon2 RC1 to boot a copy of a Retail DVD on a USB Drive, install from there to a hard disk partition, boot the newly installed partition from the same USB Drive, and perform the necesary kext/kernel/chameleon installation over the HD partition to make it able to boot from it independently (it could also be posible to keep the USB Drive as the boot device and dont touch the partition with the retail installation at all but I havent tested this scenery).
It is assumed you know what kexts your specific hardware needs to boot and work as you would need to provide them for the USB drive to boot, this is meant to be a general guide, not specific for any hardware.
It has been tested on a GA-73PVM-S2H board (n Force 630i/Geforce 7100 chipset, C2D E8200, Geforce 8600 GTS), installing from a generic San Disk USB Stick to a SATA AHCI hard disk partition in MBR format, using the vanilla kernel.
and select the USB Drive in the left: Click on the Partition tab and select Volume Scheme: 1 partition: Click on the Options button and make sure the Master Boot Record option is selected: It should be the default but its mandatory for the USB drive to boot so better to be sure.
By default the Retail DVD doesnt let you install over a partition in an MBR partitioned disk, when you select the partition to install it just gives you the choice to Erase the disk into a GPT partitioned format.
But if you need to install into an already existing MBR partition and you dont want to erase the whole disk or you just simply dont want to use GPT, you need to edit a file in the retail dvd to allow that.Click on the Apply button and wait while the whole USB drive is repartitioned into a single MBR partition with HFS format. Select the USB Drive on the left and click on the Restore tab.You have to select the Mac OS X Install DVD as the source and the Mac OS X Install USB as the Destination, dragging them from the list of units on the left to the corresponding field on the right (or by selecting each of them as Source or Destination in their respective context menu).You can also include a modded file, I think it goes in Extra too but I havent tested (if you use one you should not even need to include a disabler kext for Apple Intel CPUPower Management). I think thats all, Chameleon its too new so if I've missed something please correct me.With this you can restart the computer, configure your BIOS accordingly and boot from the USB drive.You can also copy it to the destination partition before booting from replacing vanilla mach_kernel. I followed your steps, but when I choose my Mac OS X install disc in Chameleon, it starts loading up a few kexts, says "Loading Darwin x86".. I've even tried installing the voodoo kernel, but it gets to the install screen (so, it does get further), and the kernel panics. My system either panics or gets continual reboots amongst anything I've tried so far, so it must be the kext's that is needed. Insert my custom kext for my machine to customize chameleon and make it boot.