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1.) What is a good putty to use that will dry hard to paint over? I heard on some sites spackle may actually work as well?
Putty/clay is quite brittle and heavy there are easier things to use.
Spackle/Artex is great stuff but gets heavy quickly, it's best to get as close as you can with foam or concentric shapes of foamcore and then spackle for texture.
2.) What is a good water resign to make ponds, toxic pools (for 40k)?
Vallejo Still Water or Woodland Scenics Realistic Water. They are the same thing so whatever you can get cheaper.
3.) What do you prefer using as a base, cardboard, wood, or foam?
Plasticard, MDF or Hardboard depending on the area of the piece.
4.) Do people still use a hot wire to cut through foam or is there a better method now?
Normally I use a saw, breadknife or stanley knife to rough things out and shape with a surform or sandpaper and tend to build things up in layers.
My way is messier but I have a dedicated space. I can get to where I need to be without all but the largest most expensive of foam cutters
5.) Is milliput used in making terrain at all or just for filling gaps in models?
Rarely. I may use a little to add height to a 60mm base or to join some slate together or to a base with the addition of glues.
Or maybe sculpting mushrooms, adding sculpted details or making press molds
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