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As far as I know, BackCountryNavigator does not support Garmin maps. The only Android app that I know of that does support Garmin maps is Orux. The app is free but the rendering is not brilliant quality.

Use File>Import into my collection in Basecamp.

Attach the Garmin, right-click on the KMZ in Basecamp and choose Send to...

My map of Britain is about 13GB made up of 400 .MP files, the largest is 150MB.

On a 3.4GHz i7, cgpsMapper takes about 20 hours to compile all the files; MKGMap takes 15 minutes.

cgpsMapper is no longer supported nor developed.

MKGMap will compile .MP files and works for me.

I'm trying to analyse exactly what is happening.

As I understand it, Registry-based maps show correctly in Basecamp but lose detail when installed on the device.

Garmin provide a converter to make GMAP from Registry-based files - and JaVaWa offer one too (which works for me).

If Basecamp installs GMAP files correctly then the conversion is a simple way to get round this issue. Or am I missing something?

MAPC2MAPC will cut the large TIF images from CNIG (c14000x9000 pixels) into tiles for Orux (and others).
If you use MBTILES format then you can join several maps together seamlessly.

The Spanish Geographic Institute offers free downloads at 1:50,000 or 1:25,000 : http://www.ign.es/web/ign/portal/cbg-area-cartografia

MAPC2MAPC (also not free) will convert to KMZ and allows you to select tiles for just the areas you want - the map created does not need to be a whole rectangle.

If you already have GPX  files of your planned routes then it will create a Route map optimised to cover just the GPXs

And it will make JNXs too.

[Sorry, Moderator - I declare a personal interest]

There is a calibrated version attached.

I changed the file name as some units can be fussy about long names and hyphens.

The coordinates printed at the side were a great help!

I used my MAPC2MAPC program to input the coordinates and output the KMZ.

This is full size and uses four 'tiles' of the hundred allowed in your unit.

I'm not aware of a third party tool - but I don't know everything.

pMail me and I will try to walk you through it.

But it can be done using push-pins to supply the coordinates.

Example here : www.the-thorns.org.uk/Landscape.kmz

If only the PDFs were GeoReferenced, then it would be easy.

The workflow would be:

1. Download a PDF
2. Identify coordinate points for georeferencing (see below)
3. Georeference the PDF by matching points to coordinates
4. Crop the collar to just leave the map detail
5. Cut the map into 1Mpixel pieces to make a KMZ for Google Earth and/or a Garmin Custom Map.

If you can match enough highway bends/junctions, lakes or other landmarks then this technique with MAPC2MAPC may work :
http://www.the-thorns.org.uk/mapping/GEcalibrate.pdf

MAPC2MAPC (with GDAL) will do the rest.

But I declare an interest as the author of MAPC2MAPC!

I use an iPad with a GNS2000 Bluetooth GPS and it works well.

Take care when choosing an Android tablet. Every Android phone has GPS inbuilt but not every tablet.

You could get hold of a Mapsforge map (e.g Open Andro Maps), use Mobile Atlas Creator to render sections as a PNG then use an image editor to make a BMP.

But, to me, that doesn't seem the right thing to do for a navigation system, not least because the file will be vast.

You can get USTOPO in Mobile Atlas Creator with this code :

<?xml version="1.0" encoding="UTF-8"?>
<customMapSource>
   <name>USGSTopo Basemap</name>
   <minZoom>0</minZoom>
   <maxZoom>16</maxZoom>
   <tileType>png</tileType>
   <url>https://basemap.nationalmap.gov/arcgis/rest/services/USGSTopo/MapServer/tile/{$z}/{$y}/{$x}</url>
   <tileUpdate>None</tileUpdate>
   <backgroundColor>#000000</backgroundColor>

The tiles are already Spherical Mercator and MOBAC will write a Garmin Custom Map directly.

But it seems your maps are out of date - the railroad is no more! 

MAPC2MAPC will reproject from most existing projections, doing the calculations automatically.

[I declare an interest : I wrote it]