Yep we thought the RC would be heaps cheaper as you only need to buy one and thats it whereas armies can end up multiplying continuously.  Unfortunately we didn't factor in how expensive it can be to run something that fangs it around on dirt race tracks at up to 80km an hour, they are really durable when you see how much punishment they take but your luck can only last so long.
In the boards absence I have been alternating between painting a blood bowl team for my wife and converting up more characters for this army.
All in terminator armour I have made:
1 Warmaster
5 Warlords
15 CSM Champs
7 Icon Bearers
7 Sorcerers
A sample of the characters:

I also had Audreys Obliterator Conversion Guide pointed out to me (
Link) so the obliterators I had done are getting converted over and the rest will all be done this way.  There are 60 Obliterators (20 stands) going into this army.  That should give some sort of indication of the size the army is going to be.
Cutting away from your fingers doesn't really work that great when your talking 6mm infantry so I ended up with a wicked cut from stabbing into my thumb.  I have started putting tape over my thumb when cutting the powerfist arms of the terminators for these conversions as you need to put a lot of pressure to cut through and then the knife suddenly jumps out halfway through.  Definitely worth the effort though, just be really careful doing them.
Obliterator test samples:
