An old thread, but bumping it in case someone else is on the same track.
Apart from the tried-and-true method to combine maps explained by Gary, there is one very fast method that has other benefits. (This is for the older Garmin GPS models that only accept one gmapsupp.img file.)
1. In Mapsource, you export each individual map to the card, one at a time. So for instance you export GTMaps. On the unit, this creates a file called Garmin/gmapsupp.img. You rename it GTMaps.img and copy it to your hard drive. Delete the file from the unit. [Note that this step is not strictly necessary as Gary's CD already comes with a gmapsupp.img file. Just copy it to a working folder and rename it as above.] Then export the Free Open GPS map to the unit. Again, this creates a file called Garmin/gmapsupp.img. Rename it something like FreeNZ-111014.img (the numbers are for you to remember the the map version: here 2011 October 14) and move it to your hard drive.
2. Using GMaptool (a free program made by a Polish programmer), you can join the two img files in a few seconds. (For detailed instructions on how to do that click my signature and search the page for GMapTool.) Once the files are joined into a new map, rename it to gmapsupp.img, and move it to the card under the Garmin folder (very important). You could do this to combine any number of (renamed) gmapsupp.img files, subject to your device's tile limits.
A key benefit of this method is that if you want to change just one part of your big map file (for instance, the Free Open GPS map that updates all the time), you don't need to export both mapsets again. You already have the GTMaps.img file (which won't change as often), all you need to do is export the new FreeNZ map, which is quite fast, and glue the two img files together again.
