You know ... all this scaling talk has me wondering if some of these challenges could be tackled with the new dynamic components feature in SU7.
Say ... one with a tenon on each end. One with a tenon on one end. One with a mortise on both ends. That kind of thing ... or maybe someone will come up with a single "Board" dynamic component that would let you configure each ... yeah that gets hairy quick.
I have avoided playing with SU7 Pro's trial because I'm sure I'd love making dynamic components and have to buy it :P