Danger was in charge of this. He got some poster board (green, because that's what color a field is) and drew a grid on it. After that, he added the lakes. It came out awesome. It's in 4 pieces so they stack instead of folding up.
I was prepared to just do my best drawing the images, but while I was looking for inspiration, I found an awesome collection of Statego SVG files that look exactly like the 1980s version I played.
I printed enough of everything on white card stock with a nice star on the front side. Danger cut everything out, folded it, and glued it up. I used a spreadsheet and a lot of "Print Preview" to get everything lined up for printing.
Let me know if you want the spreadsheet.
I had a nice box left over from Boccalone (where I got my "Tasty Salted Pig Parts" shirt). It works perfectly. The map fits nicely without rolling and the box has a couple of partitions inside that can hold the pieces.
It came out great. Danger even taught his (5-year-old) little sister to play. She mostly just stumbles into bombs until she finds the flag, but the extra-aggressive strategy combined with her uncanny luck is quite effective. I may post about her prowess at poker later.