incognito said:
1. Where are the Orc spell casters (are there any?)
You'll be meeting one in the next update or two. In general, however, orcs are less able to employ specialists who can devote the study time required to become a good spell caster - where Theralis can support about 1 in 250 people as a spell caster, orcs can support less than 1 per 1,000.
2. The orcs seem to have some pretty impressive resources. Why are they just now becoming a threat?
Lots of reasons. The major ones are:
* Orcs are nomadic raiders and hunters by culture, grouped into tribes of (typically) 500-1000. They organize into warbands of 20-30 orcs, who hunt over a really huge area. Usually, a tribe will slowly migrate from hunting area to hunting area over the course of a few years, covering somewhere around 4,000 square miles. That's sufficient to support the tribe, and barring occasional raids for 'goods' in civilized areas, that's all anyone sees of them.
* They are occasionally a threat. Some tribe will get a bone in their head about killing all the humans, or retaking sacred lands, or moving into sweeter pastures... and a whole tribe (usually a bit bigger than usual, say 1500-2000 orcs) will up and assault some area. Those are rough times, but it's only one tribe.
* This isn't one tribe. It's closer to half a dozen tribes, all at once.
* Impressive resources? They've got spears, drums, hide clothing, and some purchased axes. The Bunahken orcs comprise about 1200 (they're the largest tribe currently attacking Theralis), and they ended up at the more difficult Eastpass - most of the others are trying to assault the city instead.
* As to why the orcs are attacking all at once, now of all times... well, that's something the players have to discover

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3. How do the players feel about having somewhat of a "along for the ride" role in this portion of the story arc - certainly this is somewhat derailed from your 'typical' adventure in which the players are the main stars.
I can't really answer for the players here, but...
* I think Athan would disagree

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* A large part of Merideth's and Greppa's concepts are ambition to rise above exactly this. So I have to give them a taste of being one among hundreds, before I let them work their way to the top.
* We're building heroes. Heroes come from somewhere, and I like to build the 'where'.
It's more complicated than that, but I'm running out of time to post

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4. I assume you have worked out counters for each military trick, each side, that comes up. ie: the shield wall is used to keep out physically superior, or more numerous combatants, and the rams are designed to take down the shield wall - what takes down the rams? Fireballs? or something non magical.
Yes.
Neither side has really fought this kind of war before. Theralis was founded by slaves of the orcs, each and every one of whom fought for their freedom (hence the tradition of Service for the first year of adulthood). Discipline was a given, but the primary tactics evolved from a few clever generals during the early years of Thera's rule, and have not changed much since then (a few things, like the longspears and constant presence of a healer or two, were added later in their history). The orcs are fighting like they've always fought - individually, as fierce warriors, united by the heartbeat of their drums.
So both sides are learning how to fight, and learning where their weaknesses are.
A real simple trick to stop the rams, incidentally: Open the ranks for the ram, and set spears to catch the orcs carrying it. The main advantage of the rams was surprise.
5. With the capture of the adventurers, are we going to see some...errr...gritty treatment of prisoners? Or are we keeping this on the up and up.
The rating for this Story Hour is EG (Eric's Granny). Some things may be implied, but this is an instance where I prefer drama over realism.
6. there is no question 6...
Yes, absolutely. Fish.