Great project. I doubt warlord could do better.
On polystyrene balls, use a bit of talc powder mixed with them to kill the static, works a charm.
Tiny beads may be mixed in for different sizes and the holes may provide a bit of texture and variation. Even sand if its a bit smooth rather than sharp.
I made some daleks from sculpting basic bodies in super sculpy, then made a latex mould and cast a few (for my own use) in plaster. Added wire and epoxy arms and eye stalks to finish them. They look quite good, but I think I miscounted the bumps. Used them in a diorama with Crooked's awesome JP.
Another idea may be making "skirts" from card on a piece of balsa for a base and bumper effect. A small length of dowel on top with a few bands of wire for the grill/eye hole and card slats or bands (depending on era). Add a piece of GW sprue or balsa for the arm section and a thumb tac? for the dome. A bit of wire and epoxy for the arms, eye and ears. Maybe a thumb tac dish on the back?
Maybe the way I did it was easier.
Also I picked up a couple of dalek key rings at a garage sale, so shopping around can work. As for warlord's I just hope they stop at an arm and a leg, Can't blame them, though, licenses don't come cheap. Quality on the other hand… I can't help but feel they are being sculpted to maximize the life of the mould, but what do I know.
