My megadrum purchasing is coming along nicely. Just a few more selections and then I'm going to ask for a review before I buy what is left.
In the meantime, I have been reading about the trials of printing the PCB design to the correct scale. Since I have the 40 pin header, I decided to test out the print. Sure enough, like gastric, I first got a 10 page PCB, then several PCB's that were off by one pin. Eventually, I solved the problem by importing the gif into Photoshop, resampling it, and cropping a few pixels. I messed up a tiny bit and the top and bottom layers are out by about a pixel. Considering that it works out to 1/600th of an inch (0.04mm for us metric folk), I'm not concerned. The 40 pin header lines up perfectly now.
My small contribution for now will be the files that I used, in PDF format ready for printing. I hope they are of some help and that they save somebody else some headaches.