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My question is why are the boards so small ?
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From my point of view of (humble) board builder, the size was determinate by 3 things :
the size Even making a 42x22" will increase (I think) the gaming experience, and still be significantly bigger than a "factory" 6xx tudor/miggle board.
The cost. The bigger will be the board, the higher the price will be. More wood for frame, more glue, more paint, more motors. And the board itself will dramaticaly increase the price : field cover printing job is expensive and based on surface measurements. So the cutting of the board itself. A 80x42" board surface + vynil field cover will be TWICE more expensive than the "regular" 42x22" board.
The portability. For example, I've got 2 slot racing tracks in my cellar. If I count the 2 tracks together, about 30meters of track on 10meter square of surface board, and 7 players can race in the same time. But in reality, we are rarely more than 2 or 3 to play, once a month max. If I was able to take my tracks in my car and bring them in friend houses or events (town events, associations, etc...) I should be able to organize big races every weeks. You get it : it's why I choose to have a gameboard quite light and "small" (if we can say a 44"x24" -total size- gameboard is "small") so I can travel and bring the game everywhere I want : my brother house, friends house, community events, etc, etc....
It's of course my personal thoughts about that. But I think, in a league (or club, association, etc...) with permanent locals, a main giant board is a good idea.
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would a print shop have an issue printing a field that size ?
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No issue. A pro printer 's got new machines how can print several meters wide printed sheet, and even cut it on the printer out. But the bigger, the more expensive since printers will charge you on a surface base (in france they charge on a meter square base).
ah, and I forgot one thing about giant (or for 90"x45" or more let's speak about HUGE) boards : the board levelling. We certainly have to consider the own weight of the board surface (fiberboard or metal) how will collapse the field, I guess.