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so, I am due to have my first son born come November (yeah!) and I want to build him a castle, you know like a lot of people build their daughters a doll house, well my son gets a castle. anywho I remember a set of pre-made bricks with mortar and all that that you could make anything out of, I would like to know if anyone here knows of this sort of product, and lacking that How would I go about molding bricks and what material should i use, I want it to be brick like, such as cement or plaster of paris, and it needs to be strong, i plan on making this quite large and it will be heavy as it will be to the scale of a standard action figure, so say a 6 inch level and there will be four levels.

long story short i need some help and anything would be great.

When I was real young I had something like this.
http://www.321toys.co.uk/cts_m-tef-3500_teifoc_castle_brick_kit.htm

Not sure if its quite right. You may need more than one kit for your scale.

Keep looking around. You'll find something.

Nice idea - I've got 3 boys myself.

I strongly recommend you go for hardboard / MDF with hardwood struts reinforcement for the general frame. Just do a few 'cartoony' bricks on the outside - something you can easily repair / repaint / replace the odd panel on if you have to. You simply would not believe how much punishment kids put on things, and as this is to last him a good few years (of that consistent punishment) you'd best build it strong.

There are three ways to do this.

1. http://www.hirstarts.com/

2. Build the walls out of material such as hardboard, skim it with putty or plaster and scribe stone shapes into the skim.

3. Build the walls of hardboard and glue embossed plastic on the outside.
http://www.antenocitisworkshop.com/wargaming-materials-tools/sheet-materials/embossed-styrene-sheets/slaters-plasticard.html

I don't recommend plaster - sure it will look great, but will also shatter the first time the kid knocks it over (which he will).

MDF would be the easiest way to build a kid-proof castle, adding painted-on brickwork to the outside. I've seen such things for sale in toyshops, wouldn't be too difficult to replicate, presuming you have woodworking tools.

Or just buy a pile of Duplo (Lego when he gets older) and make a castle from that?

Hmm Somehow my post did not how up. I would recommend hirst art and dental plaster. Dental plaster is much better then typical plaster and is much harder to break, and even when it does it is easy to glue back together.