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I, too, cringe at the thought of purchasing figures. I'm more of an armchair modeler than modeler frankly, but with my mechanical engineering background (causing and being around manufacturing all the time...) I'm envisioning this... Some sort of sculpted figure - takes a lot of time, but cheap - maybe from wire & clay or something. I recently saw this clay-type stuff that you bake and it becomes hard - called super sculpy or something like that - ask people at a craft store. You make 15-20 different kinds, then you create rubber molds and cast your own. Yes, my approach is very vague - haven't done it yet, but this is the road I will probably go down if I ever actually get started on a layout! I remember MR had some figure building article once - I think they were made from wire with clay-type stuff applied to the wire structure.
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