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I have never put my iphone in a case as yet. The main reason for this is I have a new VW Golf which has an iPod dock in the armrest.
The trouble I have is that the dock is about 3 inches deep with very little space on either side. I will be able to alter the width dimentions of the dock slightly but I would still need to find the thinnest case I could to make this job easier.
You could try a film like bestskinsever, invisibleshield, or bodyguardz (for printed, look at gelaskins and decalgirl). For a real case though, the thinnest I've seen are the seidio innocase and cozip (off amazon.com, google for the rest).