I think your method sounds good; I'm still wondering about buying Fugawi, but not really convinced. I wondered if it would let you do something like this.
If, like me, you don't have Fugawi, I found a neat way to get 1:50000 UK maps really easily, which saves the need to buy anything! They aren't so big, but if you get keen you could probably splice a load of them together.
If you vist www.streetmap.co.uk
, and select an area you need, you can then edit the URL - there is loads of stuff in it, but there is an X- coordinate, Y- coordinate and a "Z", which I guess is zoom. If you change this to 4 or 6 you get 5km of 1:50000, or 50km of, er, well, a roadmap size map. (You can't do this using the zoom control on the page)
I then do an ALT-PrtScr to grab a copy, and paste it in to a 1000x1000 bitmap in Paint. You can then move it about to get the map to fit the "window" , (or I used to cut the map section out of the image and paste it in to another bitmap window). You can then save this as a JPG file, and you get a 600k or so file which works really well in Pathaway. (I normally compress it by 50%). My old T2 never liked loads of big maps, and this worked ok.
So you have a neat 5Km square map, perfectly aligned and in focus, and the detail is perfect. If youve ever tried scanning maps, you'll appreciate this. Streetmap will give you all the coordinates you need to calibrate it in the map manager or Touratech, and it even has the copyright message in the corner! The calibrate really well, (though often I have to nudge them in to position - what a great feature!)
It's not so good on the roadmaps - they don't calibrate properly - I reckon accuracy is not of major importance on these.
Hope this might help a few of you ... ?