I got it to work just fine. The USGS map TIFF file was 84 Mb. With the help of the map folks and some other references, I followed the external reference route. Once the entire collared map and my notes were added, I was able to print it to PDF, and the resulting file was only 8 MB. I had multiple view ports set up, so I even had a highly-zoomed in region of the map, at great resolution. A was able to plot that, and it came out perfect.
Thanks for the tips.
One thing I learned: don't waste time trying to finagle with the maps you can download for free, particulary when couple quads have to be blended and bound with collars. Much more cost effective and faster to have that work done by someone else.