As wmcclain stated, most upconvert DVD players will only output an HD resolution over HDMI. Meaning your pioneer will only output 480i or 480p over component- essentially without hdmi your pioneer IS AT BEST a progressive scan DVD player.
There is one readily available alternative in the neodigits Helios h4000 (available at costco I believe). It's supposed to be a quality drive but as the above poster suggested the question will really become: is the scaling and/or deinterlacing better in your player or your projector. Best advice is to try it out (obviously buy from a seller with generous return policy).
What to do if you find yourself stuck with no hope of rescue:
Consider yourself lucky that life has been good to you so far. Alternatively, if life hasn't been good to you so far, which given your present circumstances seems to be more likely, consider yourself lucky that it won't be troubling you much longer...
-- Excerpt from the Hitchhiker's Guide to the Galaxy.