It's awesome to hear from others who like classic scale, and how they handle expansions and accessories.
Printing PDFs at 67% is good, close to the Metagaming era counter's size (62.5%, or 5/8 of an inch.) Printing your counters at 75% would give them the same dimensions as the pocket box counters, but megahexes should be at 67%, like those provided in Adventures like Clockwork Tower.
I'm anticipating the delivery of the Pocket Box games package. I ordered several empty boxes as add-ons. Those boxes are perfect for storing additional components, since you can just carry them along with the Melee/Wizard box.
I also made a few nice hex maps in classic scale for use with TFT. One of them is 2-sided and folds to 8x4", thus it can easily be carried with the Pocket Box side-by-side in one hand:
https://www.thegamecrafter.com/games...cal-dungeon-d2
The other is not so portable, but is a large arena (27x18 inches) and folds to a fairly compact 9x9 inches. On the page you'll see some of my homemade classic scale counters.
https://www.thegamecrafter.com/games...tical-arena-a1
I'd like to know more from you or other classic scale fans, about how you adapt your components from Legacy scale.