Now I did like my d30 and only upgraded to the d60 because of hype, not in hand facts. I am leaning towards the 1600iso advantage of the d30 over the higher pixel count of the d60.
I don't think we've done a good job explaining the issues. I can't imagine any circumstances where a D30 would have an advantage over a D60. The advantages of the D60 are real - not hype.
I think part of your confusion might be due to the frequent use of pixel pitch for pixel size, and the methods by which reviewers such as dpreview compare the noise in different sensors.
I've never seen any published pixel size specs for any of the Canon cameras, but many months ago Michael R gaves us some actual sizes for the D30 and 1Ds. From memory, the total area of all 3M D30 pixels covers about 25% of the sensor. That is, whilst the pixel pitch of the D30 is around 9 microns, the actual size of the pixels is around 5 microns (don't hold me to exact figures). On the other hand, the actual pixel size of the 1Ds is very close to the pixel pitch, ie. virtually no space between one pixel and the next. Of course, the 1Ds uses a CCD whereas the D30 and D60 use CMOS sensors which have to make room for additional processing components.
For all I know, the actual pixel size of the D60 might be no smaller than that of the D30, or only slightly less. The main differences might be in the size of the additional processing components on the D60' sensor, allowing more pixels to be incorporated into the chip.
If you check out the dpreview comparison of the D60 and D30, you'll find that noise levels are very similar with the D30 having a slight edge. But this can be very misleading unless you think about what's really going on. Each of the sample grey squares in the comparison is exactly the same size on your screen. That means they are composed of the same number of pixels (90x80 I believe).
Pixel for pixel, the D30 might appear to have a slight edge, but in practice, when taking photos and making prints, the D60 gives you 2 pixels for every one D30 pixel, and the facts of life are; two D60 pixels (as a unit) are less noisy than one D30 pixel.
This leads us to the possible advantage of the D30 having a 1600 ISO setting as opposed to the D60's maximum of 1000. Don't let this fool you! Since we've already established that the D60 produces less noise, an underexposed D60 image at ISO 1000 with exposure compensation applied at time of conversion, should be no noisier (and probably less noisy) than a correctly exposed D30 image at ISO 1600.