I put together a hobgoblin/goblin military encampment a few years ago. The total population was about 210, broken down as follows:
Command Group
Leader: Boss Druzhak, 5th Level Hobgoblin Fighter, 1st Level Blackguard
Priest Furzwurm, 4th Level Hobgoblin Cleric
Underpriests Illik, Graz, 2nd Level Hobgoblin Clerics
Lugash, 5th Level Hobgoblin Rogue
Underboss Skanz, 6th level Hobgoblin Warrior
Underbosses Urbratz, Ulpash, 3rd level Hobgoblin Warriors
Druzhak’s Boys: 17 1st level Hobgoblin Fighters
Druzhak’s Guard: 10 2nd level Hobgoblin Fighters
Charioteers
Underboss Igrutz, 3rd Level Hobgoblin Fighter
Lieutenant Zgatz, 3rd Level Hobgoblin Warrior
Lieutenant Tarz, 2nd Level Hobgoblin Ranger
33 Charioteers: 1st Level Hobgoblin Fighters
Troops
Underboss Zbotun, 3rd level Goblin Fighter
Lieutenants Razzog, Igglitz, Urzz, Lugbur, 2nd level Goblin Warriors
Razzog’s Boys: 20 Goblin Warriors -- Archers
Igglitz’ Boys: 20 Goblin Warriors -- Foot
Urrzz’ Boys: 20 Goblin Warriors -- Foot
Lugbur’s Boys: 20 Goblin Warriors -- Wolf Riders
Ibble, 2nd level Goblin Rogue
Shamans Redeye, Frazz, Lop-ear, 1st level Goblin Adepts
Shock Troops
Underboss Bertz, 3rd level Orc Barbarian
Lieutenants Bryll & Ptarg, 1st level Orc Barbarians
Shaman Urug, 2nd level Orc Adept
Shamans Gurug, Tarug, 1st level Orc Adepts
The Boyz: 36 1st level Orc Warriors
Stamp, Smash, Gnaw: 3 Ogres
Specialists
Fesh, 3rd level Hogoblin Rogue
Underboss Surizag, 3rd level Hobgoblin Sorcerer
Gunk, 5th level Goblin Expert [Weaponsmith]
Snotz, Urfutz, 2nd level Goblin Experts [Smiths/Carpenters]
The camp was set in a mountain valley due south of a natural pass/chokepoint. The pass was guarded by a wooden palisade and overlooked by spotter's nests. The area beyond featured a short stone tower for the hobgoblin command and a wooden longhouse for the charioteers. The goblins and orcs lived in tents and shacks.
The adventure was an infiltration/diplomacy mission for 3rd/4th level characters. A seventh level party could probably smoke the place.
Some ideas:
Use big groups of grunts with higher level leaders. 10 or 15 goblin warriors give an Ok fight if they've got a 3rd level hobgoblin fighter to lead them.
Custom build your troops. Stat up a basic infantryman with feats and gear specific to the role. Do the same with a basic archer. The standard MM hobgoblin/goblin is too much of a generalist and lacks good equipment.
Consider the mob template. IIRC, a mob is CR 8, which is about what you need. There was also a "troop" template floating around the Wizards boards that was supposed to represent a mob with military training. I've never used it, but it might prove fruitful:
http://forums.gleemax.com/showthread.php?t=637522
Good luck!
Command Group
Leader: Boss Druzhak, 5th Level Hobgoblin Fighter, 1st Level Blackguard
Priest Furzwurm, 4th Level Hobgoblin Cleric
Underpriests Illik, Graz, 2nd Level Hobgoblin Clerics
Lugash, 5th Level Hobgoblin Rogue
Underboss Skanz, 6th level Hobgoblin Warrior
Underbosses Urbratz, Ulpash, 3rd level Hobgoblin Warriors
Druzhak’s Boys: 17 1st level Hobgoblin Fighters
Druzhak’s Guard: 10 2nd level Hobgoblin Fighters
Charioteers
Underboss Igrutz, 3rd Level Hobgoblin Fighter
Lieutenant Zgatz, 3rd Level Hobgoblin Warrior
Lieutenant Tarz, 2nd Level Hobgoblin Ranger
33 Charioteers: 1st Level Hobgoblin Fighters
Troops
Underboss Zbotun, 3rd level Goblin Fighter
Lieutenants Razzog, Igglitz, Urzz, Lugbur, 2nd level Goblin Warriors
Razzog’s Boys: 20 Goblin Warriors -- Archers
Igglitz’ Boys: 20 Goblin Warriors -- Foot
Urrzz’ Boys: 20 Goblin Warriors -- Foot
Lugbur’s Boys: 20 Goblin Warriors -- Wolf Riders
Ibble, 2nd level Goblin Rogue
Shamans Redeye, Frazz, Lop-ear, 1st level Goblin Adepts
Shock Troops
Underboss Bertz, 3rd level Orc Barbarian
Lieutenants Bryll & Ptarg, 1st level Orc Barbarians
Shaman Urug, 2nd level Orc Adept
Shamans Gurug, Tarug, 1st level Orc Adepts
The Boyz: 36 1st level Orc Warriors
Stamp, Smash, Gnaw: 3 Ogres
Specialists
Fesh, 3rd level Hogoblin Rogue
Underboss Surizag, 3rd level Hobgoblin Sorcerer
Gunk, 5th level Goblin Expert [Weaponsmith]
Snotz, Urfutz, 2nd level Goblin Experts [Smiths/Carpenters]
The camp was set in a mountain valley due south of a natural pass/chokepoint. The pass was guarded by a wooden palisade and overlooked by spotter's nests. The area beyond featured a short stone tower for the hobgoblin command and a wooden longhouse for the charioteers. The goblins and orcs lived in tents and shacks.
The adventure was an infiltration/diplomacy mission for 3rd/4th level characters. A seventh level party could probably smoke the place.
Some ideas:
Use big groups of grunts with higher level leaders. 10 or 15 goblin warriors give an Ok fight if they've got a 3rd level hobgoblin fighter to lead them.
Custom build your troops. Stat up a basic infantryman with feats and gear specific to the role. Do the same with a basic archer. The standard MM hobgoblin/goblin is too much of a generalist and lacks good equipment.
Consider the mob template. IIRC, a mob is CR 8, which is about what you need. There was also a "troop" template floating around the Wizards boards that was supposed to represent a mob with military training. I've never used it, but it might prove fruitful:
http://forums.gleemax.com/showthread.php?t=637522
Good luck!