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Just to give you a rough idea, I did a MapQuest route from Louisville to Charleston. In order to get the "avoid highways" option, the trip had to be broken down into "legs" - if the trip is over a certain number of miles, it forces a highway option. We did this on our trip to NC through TN from Lexington and also on our trip to W. Va. It worked pretty well. At least it will give you a rough idea of a possible route.
Cheers,
From Louisville:
US 31E → US 150
US 150 → US 27S (crossing into TN)
US 27S → US 441 (from Knoxville to Columbia, SC)
US 441S → US 23S
US 23S → US 76 (crossing into SC)
US 76/US 123 N → SC 28 Bypass
SC 28 → SC 72
SC 72 → US 25
US 25 → US 178/ 378E
US 21S → US 176E (from Columbia to Charleston)
US 176E → US 601
US 601 → US 21S
US 21S → US 78E
US 78E → US 52E
Cheers,
From Louisville:
US 31E → US 150
US 150 → US 27S (crossing into TN)
US 27S → US 441 (from Knoxville to Columbia, SC)
US 441S → US 23S
US 23S → US 76 (crossing into SC)
US 76/US 123 N → SC 28 Bypass
SC 28 → SC 72
SC 72 → US 25
US 25 → US 178/ 378E
US 21S → US 176E (from Columbia to Charleston)
US 176E → US 601
US 601 → US 21S
US 21S → US 78E
US 78E → US 52E
