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So I've made a bunch of components that I want to start duplicating in resin, pewter, lead - whatever works. Who's got experience in doing this, and what advice can you impart upon me? I'm about to move house and will have a well-ventilated studio room and a sheltered back yard.

Attn: I'm not stupid enough to duplicate copyrighted material, I only want to cast my own IP.

Bingo:
http://www.ehow.co.uk/how_4826999_cast-resin-figures.html

I advise you to start with resin as dropping molten metal on anything (yourself or your property) is a bad idea.
Resin casting is also the easiest way to duplicate your items.

Use a vibrating table to remove air bubbles fromt he resin after you pour; air bubbles are your enemy.

talk to the guys at Alec Tiranti (www.tiranti.co.uk).

My mate went to their shop & found them really helpful.


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for some reason their site isn't loading at the mo

youtube has seveal useful how to vids for using silicone for making molds.

Downside, small scale work isnt really covered, so alot of the intricacies of casting small parts(like air bubble problems) arent covered. But if you dig around enough you can find stuff from other gamers covering those aspects.