A while back I remember reading a contest entry for a book series where someone came up with a pocket dimension with a very heavily Chivalric Romance theme- there were fey, knightly quests, three Special knights with their sashes, etc. I loved it, and I love this too, fully expect some of the pages to eat through my printer's color ink cartridge. (Edit: JK it turns out my black cartridge died first when trying to print the weapons. Any chance we could please get a version with white background and black text to alleviate that?)

I do have a question about the journey part of the hunt; how much health/approaches should the challenges and quests consume? Like, there'll be nine challenges, and each knight has 3 quests to complete right? Assuming each challenge and quest takes one Approach (focusing on that for now), and can recover up to two approaches/one health (which I'm going to say is equivalent to one approach since a challenge could be solved by, to use an example, someone pointing the Sword and firing their Swordbeam at that reanimated knight armor instead of them spending Guile or something), so that's 9 approaches minimum eaten up, leaving a 2-man team with at most 21 approaches, a 3-man team with 36, and a 4-man team with at most 54; is this a correct expectation, that each challenge/quest should require just one Knight to spend an approach? Or should I adjust my expectation for how many approaches a Knight that bothers to do all their quests will end with?

(Also, side question: how does the Gigantic beast's Crash interact with the Knight of Stone's power? Does it just ram into/is stopped by any rocks in its way?)

You should check out the design commentary on YouTube.  There's a bit that discusses the use of Approaches and it does not just have to be one Approach per challenge/quest.  I think that's a decision/discussion for the GM and players to decide.  But challenges can be multi-part challenges.  I could imagine, as an example, one of the first challenges like "A group of people are camped nearby, no friends of the order" could be broken up into lots of different optional parts.  Find the group, find the leader of the group, gain their trust, get them to do something (help, leave, defend).   

I think the goal is for the GM to find opportunities to make the Knights use Approaches as often as possible to tire them out, or say no and take the cost/complications.  I think this will be the trickiest (and most fun) part of GMing this game is to figure out that balance.