Just to be clear, TT, please don’t see this as a critique of your pieces, per se. I actually think I rather like them in the size that they are. The issue isn’t one of perfect accuracy; in this we aren’t like the miniatures/ tactical wargamer. I think I can speak with confidence that the strategic wargamer, represented by the AAA boardgames crowd is more interested and more concerned with the overall look of the piece set, on the board, as a whole, rather than individually perfect pieces.
…So, if you did a complete set of pieces with AFV’s all set to the scale of yours, planes set to a scale not bigger than TWG, infantry to somewhere around HO scale, ships not bigger than 1/3000 scale, etc, all in affordable plastic… I’d happily fill my FMG Ammo box with them and be thrilled with the purchase!
The problem comes when you have less than a complete set from any one manufacturer and thus have to mix and match.
And the only manufacturer that makes a usably complete model line (in affordable plastic, anyway) currently is WotC, so if your goal is to create a set of accessories that supplements or fills in the gaps in their line-up, matching them in color and size is gonna be key.
FMG has promised such a set eventually, though, so perhaps filling in FMG’s gaps is the ideal project (Unless FMG takes too long, in which case an alternative complete set might be an opportunity…) You’re idea of creating a perfect board might also be a good one, perhaps supplemented with doing some categories FMG couldn’t get to in their first run (like “Superbattleships” or “paratroops”). If you two coordinated, it could be ideal: him doing a complete piece set and an awesome piece storage box, you doing a compatible supplementary piece set and an awesome new board! I’d spend some money putting together a set like that! (I already have started to, actually, having sprung for the ammo box, along with just about any AAA and accessory product I’ve ever been able to find…)
With pieces, though, the key is, to either be COMPLETE or COMPATIBLE, because if you’re neither then the strategic gamer doesn’t know what to do with your stuff and will buy some to show his support, perhaps, but not nearly as much as he would otherwise.