This was a group collaboration at NESIT Hackerspace in CT where I said I was going to make a Settlers board and everyone was so enthusiastic that they jumped in to help. I never play with less than five people so we copied and pasted some for the 5-6 player extension pack, and then hand-painted all the pieces. It was a blast. Thanks for posting your plans!
Laser Cut Settlers of Catan Board
Game board for Settlers of Catan
Reclaimed Wood Flat-Pack Picnic Table With Planter/Ice Trough