Have you attempted to use any other map data yet? I believe at one point, you said the maps you are using are being scanned in from highly detailed paper maps. I have several different map programs for my laptop and GPS, and wonder if one of these could be used easially for the data they have on CD.
Basically, all map data (the bitmaps) are stored in 4bpp BMP format and organized in a way that they are rather easy to construct from any source (web, scanned maps). I haven't seen those GPS CD-maps, so I have no idea in what format they are in. They have to use some standard but I doubt that they are in any known image file format (like JPG, BMP, GIF, TGA or such), though.
Kim