Gundato: Again though, any team would have to do those activities. And my point was more that you don't need nine people to work on the same texture, that work can easily be assigned on a person-by-person basis.
Not any team takes their work as seriously as these guys do, which clearly sets it apart of other mods. I don't get your point, each member works in his own specialization which can be level designer, prop modeller, programmer, etc... If there comes the desire to mutually add to each others work this will only benefit the quality of the project and isn't even lost development time.
Gundato: And considering that they have a team with a size that rivals some smaller dev teams, they definitely have enough people to assign work to. Sure the time spent by each person is somewhat low (adding to the overall development time), but they can pull off some throughput very easily.
I think you are underestimating the task at hand (that's even an understatement). Managing such a big team gets really messy very quickly. You can't count on each one of them to be available at any given time, you have to expect the unexpected at all times and if an important coremember decides to quit it will slow the progress considerably down.
You're repeating "easy" and I don't see how this is easy at all! As Project Leader you need to find ways to motivate your fellow workers to keep both the Developers from leaving and the mod from dying. They forced a deadline on them to have something to look forward to to get it done, on the other hand they are not willing to sacrifice their work just to meet the imposed date.
Gundato: And you yourself point out: they are (probably) matching the levels precisely.
I am going to pretend that you have painted something before (hell, let's pretend that I have :p). It is much harder to paint your own picture than it is to duplicate another person's picture. Even though you have to make your own strokes and the like, things like color and perspective have already been thought out.
So, at he very least, I think that should even out a lot of the asset recreation (which, considering the reuse in HL1 isn't as massive an undertaking as you are describing. Especially if Portal's assets are available, because they provided a lot of office furniture and the like. And HL2 already came with some assets that can be used for equipment for the test chamber and the sewers).
Contrary to what you could think, they are not matching the levels precisely to the originals! They're building it all up from SCRATCH. Improving, fixing, giving a meaning to the levels by documenting themselves with architectures, modern facilities, hundred if not thousands of reference shots they need to dig up or take themselves in order to do a believable world.
Some whole sections had to be redone entirely to match the current level of quality, gameplay mechanics, AI, scenes... This sets you back several months already!
It's actually the small details like something as trivial as assets and props that cost a considerable amount of time to get done right.
They are using almost nothing from the shared content, of the top of my head the only stuff they're keeping is the headcrab, vortigaunt and crow. This has the advantage for you that you don't need to own one precise game but any Source engine powered game that comes with the SDK.