I used my standard assembly-line painting technique. First I removed all the flash using hobby snips and an old x-acto knive. Then I filed down the bottom of the bases so the figure would stand on its own without assistance. Minifigs are notorious for having excess lead on the bottom of the base.
Next I installed pikes where needed - most figures came with spears attached fortunately. On those that did not, or those with broken spears I drilled a hole in each hand using a dremelski (you can get really cheap ones at Harbor Freight for under $20 - less if you used one of their 40% off coupons) and a 1/32" drill bit. I cut pikes from 1/32" brass rods (you can get them at hobby stores and my local Ace Hardware carries them). I superglued each pike into place. Some hands were not big enough for the hole so I used model putty to build them up.
Next I glued 4 figures to a popsicle stick using normal school glue (PVA). When they were dry enough to handle (a couple of hours) I spray painted the figures using white Rustoleum Bare Metal primer - this would also be the final color of the majority of each figure i.e. their tunics and linen armor.
Once dry, I painted the figures using el cheapo acrylic hobby paint - skin tan, spears, scabbards and belts brown, capes and crests red, and some kilts red. I painted the shields gold and dipped the tip of each pike into a pot of thick silver paint (this also gives an effect of building up the spear point on the end of the pike). Standards and musicians and some officers needed special attention (hair, horns, swords, standards).
I use an assembly line - painting with one color at a time. This way I can quickly see what item needs to be painted what color on each figure and speeds up the whole process. When they are all done, I touch up any spots that I missed or that got splashed with the wrong color.
Then I washed the whole lot with Minwax dark walnut wood stain thinned down a bit with enamel thinner. That has to dry overnight or else the sand from the next step sticks to it.
While that is drying, I made the bases. I use old beer coasters I filched from pubs in Germany during my 10 years stationed there - they are the perfect thickness (about 1/16" or 2mm). First I spray paint one side of the coaster a dark brown. Next I measure the size of each base on the coaster with a ruler, pencil and T-square. Since most are either round or have rounded edges this can be a bit of a trigonometric drill to maximize the use of each coaster. Then I cut off the excess bits around each coaster using a Fiskars rotary paper cutter (a bit pricey, but if you use a Michaels or JoAnn's 40% off coupon you can get a good one for under $20 - cheaper ones work too).
Then I affix each square/rectangle containing 20 or so 15mm x 40mm bases to Aleene's magnetic 'tacky' sheets ($5.49 for a pack of 4 x 4" x 6" sheets at Michael's but once again cheaper using the 40% off coupon). I love these things - adhesive on one side so you just press the coaster bases to it, with a bit of heft and thick - about 2mm or 1/16"). Then I use the rotary cutter the chop out each base. I needed 36 bases.
Then I pry each figure off the Popsicle stick and spread a bead of wood glue mixed with brown paint onto each base. Some of the figures that had trouble standing on their own got a drop of super glue under the base to assist. I place each figure on the glue-covered base, use a toothpick to spread the glue on the base of the figure.
When each stand of 4 figures is ready, I carefully slide the stand into a tray of regular old beach sand that I have poured into an old plastic cookie tray. I let that stand sit in the sand while I prepare the next one - I carefully remove the one from the sand and set it in an old foam bratwurst tray and insert the next one.
Then I let the whole lot sit overnight to dry. To finish it all up, I use a brown paint pen to paint the edges of the bases.
For more pictures of the process, see my Painting Guide post.
Voila! 144 pike in a week. I may go back and add some shield designs or decals later.
Next up was some light cavalry. Over the years I have collected a load of various Greek cavalry figures and miscellaneous horses - just a jumble in a storage box. Lots were broken, some were just given to me, others were left over from other projects. Mostly a mess. I also had a bunch of old shields that I had cut off some Balaeric slingers, as well as the odd hoplon (and even some old thumbtacks).
Using the same process as described above, I was able to paint up 24 light cavalry in 24 hours - from start to finish. The only real difference is that I did not let the wash dry overnight - this meant that some of the sand adheres to the legs of the horses after the bases have dried overnight - easily removed with a soft toothbrush (make sure you do this prior to any dull coating).Ta da! 24 light cav in 24 hours...
great system!
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