Let me know if this helps.
da Hugh
Wow, Don, you've been doing a lot of research! Have you posted photos anywhere? Have you considered talking to your library about another display? An educational thing like that would be up their alley.
To Justin:
I've settled on 20 guys to a century, with a centurion, optio, and standard bearer.
For cavalry, 8-10 riders is my turmae, with a decurion, duplicarius (no sesquiplicarius), and vexillium bearer.
These turned out to be physical necessities due to space and resources. A twenty man century is so big on the table I can't do much with it. And, I'm modelling different auxiliary cavalry troops (Roman Gallic horsemen, Numidians, and the emperor's singulares) and running short of equipment.
I'm not attempting to model a cohort, but a garrison out in the middle of nowhere with maybe a legion marching through. With the Egyptian theme coming out, I'm tempted to overhaul my display and move it to Syria from Britain. (I'm currently using green felt terrain but could swap some of it out for desert brown. Actually, Syria has (or had) forests, right? Didn't the best cedar in the world come from Lebanon?
My barracks is scaled down considerably and actually resembles the barracks of a fortress instead of the bunkhouses of a fortlet (the fortlets were considerably more spartan--even the Decurion's room was normal sized compared to the rest of the men (vs. the centurion's fortress dorm which was 7 times as wide as a regular barracks room).
My biggest problem is I like modelling aspects of the legion, but they don't have a place in my scene, of an auxiliary fortlet. Even the catapult and scorpions are out of place. I may have to clear off space on a shelf for them. My "Roman" scene will probably end up having very few actual Romans....
-Tim