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So I was reading a 40k star map earlier and i;m curious as to how far the Imperium expanded before the heresy. Was all the that Imperium now controls reached by the crusade or have new worlds been added? what was the max extent the crusade reached any help is appreciated and if anyone has a map they could use to show the extent that would be awesome.

The Imperium now is slightly smaller than that of the Crusade I think.

The Imperium is significantly larger. The Tau Empire had only just been reached and many areas were still unexplored.

Read the stories about Lord Solar Macharius, the man who took the Imperial armies further than they had ever, ever been. When he reached the edge of the reach of the Astronomicon, and his men refused to go beyond, he fell to his knees in defeat and wept that he could go no further for the God-Emperor of Mankind.

His name has been used as the highest honour which can be bestowed by the Imperium ever since - to be named the Lord Solar.

The Imperium reached its peak in roughly M38, a period known as the Age of Redemption which saw Heretics purges by the billions, Xenos forces pushed back, and many new Crusades which pushed the Imperium's borders to their peak.

However the Imperium began to decline by about M41, a period known as The Waning. Their military became overextended with all the new territory/campaigns launched in the Age of Redemption and the emergence of new major threats such as the Tyranids/Necrons has resulted in the Imperium slowly losing ground day by day at the end of M42 and the grim reality that they're doomed.

The great crusade reached almost every world colonized by humans. Some were lost in the heresy, some exterminated, others found later.
I'd guess most of the worlds humans have settled on in the DAoT and still populated in the age of the GC were found. ~ 70 - 80%