I use a lot of mass combat in my FR campaigns, usually 50 - 100 men and monsters all in all.
It's quite quick and fun if you keep close to that guidelines:
Make armies effective in large numbers. just beef up the stats and bonuses to make sure the outcome is realistic and doesnt take for ever to resolve, or be dominated by the heroes alone.
Use fighter stats instead of warriors, make predefined mass stats for each type of specialist (infantry, archer, knight)-
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keep in mind:
- troops are only effective when there is someone to lead there (veterans at least 3rd level) and at least another guy shouting commands etc... without those guys morale and effectivity should drop. As long as those guys are around give +2 Morale Bonus on attacks in melee and +2 on will saves against fear for the lesser fighters.
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Massive armies need to act simultaniously or they are difficult to control and to overlook. ---> all have the same initiative but use a certain command hierarchy that tells them what troops act first etc...
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Large armies should have Wizards that specialize in counterspelling and are protected well. (give those guys +2 competence on dispelling checks as Feat or something)
Give them enough Dispelling and the typical counterspells to last the battle...hey its a fantasy world they KNOW what to expect!
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No godly oversight. don't allow that especially for the Players who think that a huge Battlefield is something that can be overlooked with ease and reacting much too quick and too well to things. Remember people do give cover and concealment to everything behind them!! Clashing armies are a very chaotic event and impossible to overlook when youre in the middle of the bloodfest.
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When outnumbered 1/10+ start giving out immense group boni against stupid PCs. for every 5 "organized" men another +1 group bonus in addition to flanking etc..
Heroism is good but organized fighters should never be underestimated.
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Ensure that the battle is EVEN....if you notice weaknesses fill the gap with a proper solution.
Do not fear to counter unrealistic things with unrealistic solutions
it's a fantasy world damnit!
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when attacking large groups, take dice together (usually 2 or 3) and when enough damgage is done just remove complete casualties...dont bother for "wounded" ....far too much detail slows it down.
Example: 20 Archer shoot 20 Soldiers.
Archers have BAB1 +1WF +3dex +1MW Ammo
Sorldiers have AC 18 banded mail +shield 8hp (1HD half d10 +3 Con)
10 Archers hit. You decide to take 2 dice together.
dmg total(d8): 13, 11, 9, 8, 5
and check a big 5 on your notepad for unit A.
Easy isnt it? And this result is fairly realistic imho!
--> Only attack those nearest to the unit: there is no time for picking people out behind the ranks.
If its not clear who is hit, decide quickly by percentage roll.
crits are assigned randomly to those that have been hit by the unit.
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Use cover as much as possible.
remember crossbow units can fire and reload while prone.
Archers behind walls can be very frustrating when they have the chance to duck or hide after shooting. (5foot step)
Use Polearm troops behind shield walls etc...
Very funny, but keep in mind that Battle Lords in a fantasy world arent dumb and know what to expect even in the worst case.
Mages, Summoned Monsters, Fear effects, Sleep etc....
For such things there are easy solution that are quite realistic and fit the picture well.
Magical banners, or battle horns that help out against fear and sleep. (counterspelling those effects)
Battle Wizards that are good at counterspelling and watch the battle in very closely and without hesitation. (they should be clever pro's)
Seeking help from diviners---> knowing how many enemy wizards will arrive etc...
If the enemy or the PC's have lawful alignment agree on a fair Battle without lame powergamer tricks.
If the PCs are Munchkins let there be a dead magic area directly where they go :O)