Well, there is already a Playmo-Legion on its way through Germany....
http://www.klickywelt.de/viewtopic.php?t=27268
http://www.museen-aalen.de/sixcms/detail.php?id=53844&_bereich=1599#
It about 5.500 strong. thats a table-top to really impress the neighbors...
best,
socrates
EDIT: looks like Justin and I posted simultaneously... chronologically, I'd meant for him to go second after correcting my mistakes!
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That legion is conceptually impressive, especially considering it came before Playmobil produced the enhanced full theme.
But the legion suffers some problems--the average soldier in an imperial legion didn't wear crested helms. Later that army is presented on the march with donkeys following each century. baggage was clustered toward the center rear of the army with legions in front and behind.
To Martin:
If you haven't yet, I'd recommend picking a target period for your army (it sounds like you have chosen late 2nd century, a pretty good time--Justin has argued that PM has the look of that period.
As for paper strengths--you don't have to honor that. Cavalry, for example, frequently rode out understrength, including, in rare cases, men riding mules (roman horses were smaller then, and mules could keep trot with horses, just not gallop as fast).
Unfortunately, I don't have any figures for auxiliary compared to citizens. Your horse estimate sounds good. Foot auxiliary must have outnumbered foot legionnaires. But whether a legion had a quota of archers or slingers or spearmen or light skirmishers I don't know. Something nobody here has really modeled are Balearic slingers. They could basically be the shepherd from the nativity scene wearing a baby-sling filled with stones.
There was also an auxiliary unit called the equitata. Horsemen and infantry mixed. These were probably ethnicly germans or gauls (they trained to run with trotting cavalry). Scholars have trouble figuring out whether Camp X was a pure cavalry unit or an equitata unit.
Don't forget the artillery. According to Graham Webster's "The Roman Army", each cohort traveled with one artillery piece hauled by wagon (10 per legion). Whether he means an onager or a scorpion I don't know. Probably a scorpion and its ammunition.
Also there were different shades of cavalry. Light scouts (spear and javelins, avoided melee). And heavy cavalry (they charged into the fray with lances (spears)). Cataphractii entered the army later, but probably past the time of Playmobil's representation, when Rome was investing more in cavalry than infantry.
But to give you a generic legion:
80 legionairres with one (or two) javelins each
1 centurion (carried a vine staff for discipline)[equated to a sergeant major but I'd say company commander]
1 optio (carried a long staff for swatting laggers; I've seen him in forward plume with feather on each side)
1 standard bearer (who also managed treasury and soldier accounts)
1 tessarius (training officer -- don't know what he looked like)
I don't know whether each century had a cornicern but it makes sense. centuries continued to administratively fall into maniples (two century unit) but they didn't fight as maniples. in equitata units, the maniple = one century of infantry and one of cavalry). The optio, signifier, and tessarius were immunes--sort of like sergeants.
Each tent group had I think a wagon for their tent and one donkey. The centurion had at least one horse, maybe three and his own donkey.
Cavalry lance (correct?) the smallest cavalry unit
30 men
1 decurion (centurion)--his helmet differed from regular centurion; use your ingenuity)
1 secundum (2nd in command)
1 tertium (3rd in command)
I don't know whether secundum or tertium also doubled as standard bearer / musician. It seems that one of them would, since signifiers had special privileges and rank.
As for rehorsings--
Decurion had three horses, secundum two horses, and I think the tertium also had a spare.
The regular men apparently rode with no change of horses, and this is one reason maybe why the cavalry units often ran short. Augustus Caesar purported fielded a 500 man strong unit of cavlary that had no horses! and fought as infantry.
Cavalry were administered differently than infantry. But my memory is fuzzy. Ala ("wing") was the largest division. What the 120 men unit (four companies) was called, I can't remember.
Maybe Justin will weigh in and clarify some of my mistakes. There's a great cavalry source book out there but I don't feel like digging the book out of the basement....
-Tim