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so i made a tutorial at last

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Wow, I have about 7 steps less than you when I do it. I copy, paste into MS paint, use the sizing tool to cut my borders to where I want them, save as a PNG and then open in Posterazor in roughly the manner you do. The total process start to finish for a map takes roughly 2 minutes and cuts out all the fiddling with the image itself.
My only real criticisms though (other than the number of steps and using GIMP) over yours is the 1" overlap in Posterazor and not playing around with the orientation button. That's a HUGE waste of paper. I've seen orientation drop my printed page count by as much as six, and I've seen dropping my overlap to 0.1" drop the page count by just as much. Wasting paper is not good for the planet, but if you're not interested in that, on particularly large maps or in scenarios with lots (I'm looking at you Orders From the Gate), this can cut your map taping time by like 10 minutes a map.

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Mr. Manning does make exceedingly good maps!
I just dump onto paint then size it so I get circa 11X9 squares per A4 page usually with a very narrow margin. Then cut and glue. Works fine but the squares are approximately 1" and Chris's tend to look much more exact. That said it has worked but I will be trying Chris's method for the print run for next games day's scenario.
W

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I can do most maps start to finish in just a few minutes - it was meant to be a basic guide, and there are lots of tweaks I left out to make it simpler. I mention the orientation part later on in the guide, as its far easier to skip back and forth to find the best fit.
I use an A3 laser printer at work, and find its best to allow a generous overlap as although it's a very expensive printer, its not that accurate..and I dont like white lines where the pages 'nearly' meet

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I use an A3 laser printer at work, and find its best to allow a generous overlap as although it's a very expensive printer, its not that accurate..and I dont like white lines where the pages 'nearly' meet
You still don't get those white lines at 0.1" of overlap. Trust me, you're adding in a ton of extra work for very little reward by using 1" overlap. I use a home HP laser printer that's probably just as inaccurate.