Never saw any response by someone who actually used your code and instructions to create these larger segmented Topo maps that could all be downloaded onto a 2GB card and used in the GPSr. I used your routine last week and it worked like a champ. When looking around for a way to solve this problem, I found your post and this one:
http://www.groupsrv.com/science/post-2197256.html
I tried both approaches out a little over a week ago. Running at the same time, it took about 48 hours for them both to complete. The other method mentioned above "seemed" to complete OK, but when I checked out the map segments in the GPSr, many of them were not available and I think this is probably due to the GPSr addressable map segment limit. However, with your methodology, I have the whole Topo US map set available in my GPSr. Thanks a bunch for making this available. It worked great for me.
Russ