We've been talking about how the whole board is going to be made for Robo Rally. My sister is still trying to draw up elements (squares). However, I had a realization the other day, that there's not a good reason to limit the board size to 8x8 squares (with a boarder). Turns out, we can make it much bigger than that. So, the plan will be to make it 12 squares on one side, and at least 12 on the other side. With the parts I currently have available, it looks like I could go up to about 18 squares, on the long side.
Yes, that's getting large. :)
Never fear, we're still making progress.