Guess everyone knows there's an entire forum devoted to growing your own tobacco. I'm a member. It's at How To Grow Tobacco
There is a most interesting thread regarding growing your own to be found at this link. Pay particular attention to the posts by a user named "tekwyzrd." Pictures of his 2007 crop, which he is presently smoking, can be found on page 2 of that thread, while pictures of some of his dried Virginia Gold leaf can be found on page 7. Page 16 has several photos which show the size the seedlings should be before hardening off and planting in the ground. I first saw photos of his 2007 crop two years back in the old forums. It had never occured to me to attempt the same, nor would I have thought it possible had I not seen his photos.