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Just a general question.

During the Terran Crusade, it is stated that around 4000 custodes died defending Lions gate. Now, given their elite nature, that's probably a significant amount of troops that were killed.

Has it been stated anywhere that new Custodes are being created? They were a special breed apart designed by the emperor and if I remember correctly their creation process was complicated and lengthy.

They can be created. Says so in the codex.

The creation process in complicated and lengthy, but the Custodians get to know just about all of the Emperors secrets, inculding how to make more of themselves.

And there are about 10,000 when they're at full strength, so that 4,000 was 40% of them at the time (since replaced).

Always need to be more of them, and they have the capacity to replenish to their 10,000 capacity. What can’t be replaced is the experience and martial prowess of those 4,000 veteran custodians that perished. You won’t see the inexperience of newer custodians represented in the rules...