I did this map to test a new flat bed printer (Acuity 8'x10') and routing machine (icut) we got at work.
The original was printed out at approximately 4' by 3' on white styrene (about 3mm thick) and then placed on the cutting table, where it was cut out, mounting holes drilled across the top and bottom and the corners rounded.
Printing took less than 3 minutes and cutting took about half that. The quality came out really good. The original is propped up on top of a bookcase in my office. I'll hang it on the wall when I get a few minutes.
I did the base map in Photoshop and the text was added in Illustrator.
Some time in the next few days, I'm going to try and get a color version done of this or possibly a different map, and see how it does.