I got the files from Vassal. They're in in there as SVG files. I then opened them in InkScape. When I get the files from Vassal, they don't have unit numbers. So I add the unit number, then export it as a PNG file.
I did make a change from what I had done earlier. Mike, you said you like to use 100x100 pixels for counters. I had used the original size of the SVG files in Vassal, which was just under an inch.
In the attached picture, I snipped it out of TTS. The top left counter is the one from BB, the top right is one I did. The bottom left is how I was originally doing it with sizes of less than 1" squared. The bottom right is the same unit using 100 pixel squared. I diffidently will be using the 100 pixel square method.