[scottandme]

So going off of the 39-48 teams estimate:

Why not just directly implement what MAR and FiM do, but skip the Regional Championships aspect?

Hold two "district" events, and have every team compete at both events. Practice matches/inspection Thursday night, 10-12 qualification matches Fri/Sat AM, and then eliminations on Sat afternoon. Repeat at a different venue. Award RCA, EI, and RAS at the 2nd event, and then qualify the 3 highest rated teams by points. Every team would get 20-24 qualification matches, you would have two sets of elimination matches, and there's no problem if teams come one weekend and not the other (separate schedule). If you have ~42 teams, you should be able to squeeze in 12 qualification matches (same as MAR/FiM). If you end up with 48 teams, you would still have 10 qualification matches (same as the current KC Regional).

With a little more growth, you can go to 3 district events. 48 teams would give you 3 district events with 32 teams at each. Add a district championship if/when you grow to ~4/5 district events (80-100 teams).