Thank you everyone for the compliments and interest in the terrain. I'll try to address some of the questions/issues raised by you.
This board's terrain surface measures approximately 68" x 47" and comprises 208 hex tiles. With the true 1:1 scale Micro Melee rules I use this gives an actual gaming area of 570 x 400 yards, which allows for medium to long range shots across the board for ordnance attacks and extreme range attacks by MMG/HMG. The frame containing the tiles is held together by rubber bands which makes it flexible enough to adjust slightly to eliminate some of the gaps between tiles. I have two other frames to use for smaller actions that hold 113 hexes (440 x 280 yard area) and 80 tiles (300 x 200 yard area).
Although not perfect, the GHQ Tile Maker system works for me because it is the best compromise between flexibility and hard-wired terrain. I know the hexes don't appeal to a lot of people and the alignment/gaps can be off-putting, but I can look past that to get the contour and terrain form that doesn't work as well in a terrain mat arrangement (INMHO).
The downside to TM clearly is alignment/gap issues. The much greater upside for me is the terrain configuration flexibility, storage/transport (I used to have a couple of dozen 4' x 2' boards for 25/28mm and 54mm scale games), and, IMO, more realistic contour and terrain form that hardwired terrain allows. I have between 350 and 400 completed tiles now and can store them in a 10th of the space required for the previous larger scale boards. This is also going to allow me to create desert terrain and expand my miniature gaming beyond the east/west Europe theaters I've done so far. I also use the TM terrain for the other periods I have: 6mm Napoleonics and 10mm ACW (as long as I don't use 6mm forest hexes!).
I'm not sure my alignment/gap situation is much different from everyone else who uses the TM system. A 1/16" alignment difference is significantly more noticeable for 6mm scale than for the larger scales, as evidenced by the RR tracks in the photos. The hex gaps also may not be as apparent because of the camera angles I use, the adjustment allowed by the flexible frame, and the use of separate flat/thin building tiles placed over the flat TM hexes, which cover some of the more glaring gaps.
Although I measure alignment twice or three times in constructing the hex tiles there will always be some minor discrepancy, but for me the 90-95 percent TM solution is fine.