For quite a while now I have been using the http://garmin.openstreetmap.nl/ to load any maps I might need, especially if I visit another country. However, of late the second email never comes which points to the download.
Anyone got around this?

Probably getting caught by a spam filter somewhere. Check any junk mail folder etc.

Or if you select one of the “predefined countries”, you can usually download it directly from that webpage. So no need to wait for any email.

It seems there is currently a problem with the server. Generating custom maps doesn’t work, so you won’t get an email. See http://forum.openstreetmap.org/viewtopic.php?pid=514608#p514608

It should still work for complete country maps.

Have you tried using the websites with the more specialised Open cycle maps (based on the same base maps).

https://www.velomap.org/

https://openmtbmap.org/

As welshfarmer said, but if you are using then for routing it is worth reading the notes on the site to get the best out of them.