I too have come to the conclusion that Kings of War (KoW) is a fun, affordable and easy to learn game.
Few thoughts:
- I play KoW half scale, eg 15mm miniatures, smaller base sizes, distances and range halved. This is much more manageable on a "normal" table, even if not as accurate. Good enough for a boardgame like experience IMO.
- Instead of using expensive and tedious to collect miniatures, use pieces of printed paper to represent units: doesn't look as good as "real" miniatures, but allows to try out different things. Collecting miniatures is fun, but if you're after the strategy part, and/or the boardgame experience, you don't absolutely need them. It is also sad to start collecting one type "because they look good" and hate how they play...
- I have looked into spin casting (because I could not find satisfying 15mm fantasy miniatures). It sounds like an interesting thing to try out in a hackerspace. Also, read this: "Guerrilla guide to CNC machining, mold making, and resin casting"
http://lcamtuf.coredump.cx/gcnc/ Having access to a 3D printer and a lasercutter opens interesting options for wargaming, too... even if there aren't that many free (as in free speech) designs out there yet (to my knowledge).
I have started to write an "introduction to tabletop wargame for beginners", based on free KoW rules and paper units and landscape. I am a bit worried about releasing files for these paper units and encouraging people to use them instead of buying miniatures from Mantic, but hey! It is a good way to get new people to play, so it might happen once I am happy with my designs.