Christmas is a seemingly realistic target but should time gt short I'd argue we tear up the deadline and don't compromise on greatness , great execution and playtesting.
Regarding the map I'd say an area twice the size of the current maps has huge benefits so long as the scenario editor can handle the format?
I'd also say the new map would be one of the biggest spin off benefits of the project. (Having all the cards and materials for a stack of iconic friends and foes all ready and waiting for folks to use in future non-movie scenarios and campaigns being the other).
We wouldn't need to enlarge many of the stones etc because the need is for more useable space to run and fight - basically the same features spaced out rather more, this means the extra is mostly desert floor, sandy paths and the odd scrubby bush
I'd also argue for a lot more clever and devoted hard work to break it into two normal sized mapboards that can be combined along more than one edge. Lot of hard work making zoning fit together each way but the prize is this:
Consider this map stretched to a landscape rectangle cut into a left and right side. Slide the diagonal colonade to the left enough that it's entirely on that tile and twist it a little so it makes a processional up to the offset hill top left (somewhat enlarged). We already have a large offset hill on the right side board. Put them together as they are - Battle of the mounds.
Rotate the right board180 degrees and bring them back together and you have diagonally opposite hills a natural map for even conflicts where each team has a base to attack from and to retreat to.
Instead this time join the maps along the two edges furthest from the hills and you have an ideal "capture the flag" map with a goal at each end. Or get the thingy from the hill of heroes all the way across to the mound of madness through a running gauntlet of blocking beasties.
We've a lot of undead in our pledge boxes, and these map boards used singly or in combination are covered in burial mounds both great and small so don't for a second underestimate thier future value for getting those into play. Those pirates need a deserted desert island rich in landmarks to bury thier treasure - tense times what with there being no honour among thieves and that going double for rum soaked sailors or mutinous dogs.
One or both of those hills needs a shadow that could be just cast by that rock or when needed taken to represent an entrance. Then it's diggings of grave robbers (see honour among thieves and raise you a released guardian or a triggered curse ), the weathered entrance to an atlantean tomb, a beast (scorpion anyone?) lair, a damaged ley line, or a race to stop the sorceror before he digs up the last piece of the staff/girdle/statue of someone darkly famous. Put an altar in the middle of the hill with a stone circle and you have the only place the possessed prince, the gorgeous nymphette or the kicking and screaming demon can be saved from the curse (or finally killed).
That's my two penneth ;0) did I mention I love this project?
Again the work it would take to match those edges together is not to be understimated but wow would we have something worth the trouble of printing and mounting properly.
Let's give it a go, none of the hard work already done would be wasted thank goodness, it just needs sliding over, spreading out and the gaps filled in with more desert.