Well, I finally decided to buy these:
http://www.rpgnow.com/product_info.php?products_id=21041&

And I've started cutting a few out and putting them together.  I had a sample from a few months ago and I couldn't decide between theses and "Dwarven Forge" or whatever.  In the end, I didn't want to drop $100 or so for just the basic set of those.

These are pretty good, durable enough I hope, and I was really impressed with the variety included even within just the basic set.  I'll bring them regardless of what we play next.

Wow how reusable are they, from their site it sounds like they are 1 use?

Completely reusable... you just assemble the dungeon walls and doors and items, etc.  They come in 2-3 inch pieces typically so you just place them together to match the layout of the dungeon.

The only issue is how durable are they?  I'm just printing them on cardboard and I have to choose a cardboard I can feed through the printer so they may only last a few sessions.  If that happens I can always print and assemble more.

Great idea...might make it much easier for a remote person to see.

yeah that makes sense.  I suppose they could be glued to thicker card board or laminated.  Nah laminated won't work, when you cut it they separate again.  I wonder if they could be glued to balsam wood.  That comes pretty thin, but card board would be just as well and cheaper!

I wonder if you coat them with lucite or acrylic?  Either would make them water proof at least.  They might react with the ink though and blur the images.  May be I can try that on some worn out pieces for you... once some where out that is. :-)

We may need to mount the camera higher though...

We could try it on a new one... It just takes 5 minutes to fold one together.

Even more reason to start at 2 next time...for a folding test of camera, etc.  I'm sure it will work, but it will take some time.