The problem with the Orions are that Galemp didn't realize what I had done with the nameplate texture when he did his reskin, and so the "extra" nameplate polys were removed and replaced with the old style on-hull nameplates. The one you should be using should work just like the retail Orion, as that's the way the "final" version ended up working. I'm not really thrilled about it as I changed it in the first place to ease the burden of making nameplates, but what's done is done.
To answer your question though, you should ALWAYS be scaling the whole image. If you rescale it so that the edges are still the edges then tiling will never be an issue. UV coordinates are relative to the normalized space of a texture, not pixel-specific. The corner that starts out as 0,0 will always be 0,0; the one that starts 1,1 will always be 1,1. Think about how the game handles upsizing internally; it's a stretch, not a fill.