Based on the modules I've seen that look really nice, a standard GMT map, which is 22x34 inches should be around 3400x5400 pixels as the final image size. Here's the trick--completely ignore the DPI setting and just set your pixel size. VASSAL doesn't look at a .png's DPI, so you don't have to either. Just set your pixel dimensions. Set it to "constrain the proportions" and then simply enter one of the numbers--say 3400 for the shorter dimension. The computer will figure out the longer dimension for you. It's usually best to split the map into 4 sections and assemble in VASSAL. Counters work quite well at around 60x60--enough space for legible print. You can make the map larger if hexes need to hold non-stacked counters, or if the counters themselves need to be larger to hold all the information. If you download one of Gary Krockover's modules and look around inside, you'll find examples of map size, counter size, and great examples of how he puts the actual module together. I don't think Gary does much in the way of Java coding for his modules so they are great examples to look at since there is nothing hidden going on in them. Unless you have a lot of card scans, or a map made of many 22x34 inch sections, this will keep your .mod size below the limit for posting on vassalengine.org
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