Tutorial link (courtesy of member zehn, aka Benny):

http://www.engadget.com/entry/3868866008819632/

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Here's a site where several photo mosaic programs are compared (feature-wise):

http://www.aolej.com/mosaic/compare.htm

thank you, danny :)

Craig

There's a free one called PhotoMosaique that I don't think is listed there, Danny. I played with it quite a while back, but I don't have it on my PC right now.
http://www.photofiltre.com/