Agreed about the SM minute idea. When merit badges are taught by someone who is passionate about the topic they are well done, even if they talk a lot. They find the topic interesting, they aren't reading from a book, and they are animated. That enthusiasm translates to the boys. When it is someone not passionate about the topic it is dry and boring. At least most of the time.
And yes free time is important, having a bag of games or balls in the trailer are an important team building tool.