Thanks for the well thought out replies and going into some detail. Allow me to reply to some of it in more or less great detail.
For anyone who just wants to look at pictures of my army (as promised), scroll down and ignore my ramblings.
To reply to S.O.F. here, I do believe your answer provides two problems:
1) I know in my heart of hearts, of course, that you are right but admitting to this would also include admitting that my life´s goal is unachievable and would shatter my hopes and dreams and leave me an empty husk of a man. It took me more or less the better of 20 years (some more, some way less active) to get to the better of 2000 models in my army. I dont have the 200 years it would take to get to 20.000
2) Jokes aside, I do believe that a big problem here is that we are dealing with fantasy numbers and contradicting source material.
While we are presented with some numbers for states and cities, other books, often Black Library, tell of way bigger numbers.
The storm of chaos was supposed to be hundreds of thousands of invaders. Hard to beat of your state can only muster 3000 infantry.
Much of the source material can be contested or numbers are highly exaggerated. Also factoring in a fantasy economy and magic it isnt that surprising that real world numbers dont add up in the context.
Well the thing is that though the Empire Army Book has put it as Arch Lector for the character entry, it is probably better to think of it as just a more important priest in the Order of the Silver Hammer, that is the militant arm of the Sigmarite Clergy.
I do agree with this point and largely handle it the same way. I often refuse to believe that a GRAND MASTER, as an example, of his order, would ride out with his 30 buddies to hunt down some Goblins.
I often treat the big names more as Chapter House Masters, or high ranking members of their orders.
Free Company represent ad hoc regiments mustered of either mercenaries or militia to supplement the man power of the regular state troops. Averland probably keeps a number of these regiments under arms at all points more along the lines of mercenaries rather than the militia one though.
Flagellants would not be part of the standing force but most likely found on campaign drawn from the destitute refugees fired up by Warrior Priests of the army.
Agreed, I dont really count these as standing forces of a province but more as auxiliaries.
An Army could most likely have any numbers of free company but in order to maintain battlefield order I do believe they wouldnt make up more than like 10% of an army. They are untrained locally recruited people willing to help out, but one would want the brunt of the army to be state troops.
Averland is largely isn't considered a province renowned for it's archery but the foothills of the Black Mountains are abundant in game and their are a good number of hunters and trappers there. The Mountain Guard which garrisons the forts around Blackfire pass are supported by Bergjaeger, elite archers from the region, so a number would most likely be part of the Elector's household as well.
I tend to treat my Bowmen as Bergjaeger or local woodsmen militia. In my mind Bergjaeger are more their Regiment of Renown
While the contributions of major secular or templar orders to the regular Averland army would be modest this does overlook that Averland undoubtedly has a number of smaller local orders. The Order of the Black Bear is about the only one that comes to mind as an official Averland secular order but there would be others as well as whatever Knightly bodyguard the Elector employs.
Could we apply real world numbers here? Not sure. Some English battles literally had thousands of knights (Agincourt) while sometimes 200-300 knights were considered a massive force. I have about 300 Empire Knights, please dont tell me I need WAY more
While the majority of artillery pieces built in the Empire are cast in Nuln, not all of them are. The ratio and number of guns is complete guess. Historical armies of say the mid-16th century might have 100 field pieces for a 20-30,000 force but the Empire seems to use artillery to a greater degree than real world counter parts. Further if this project is say scaled to the Electors troops at Averheim the number of guns would by higher as it would include not only the amount normally allotted to that size force but the reserve kept in Averheim as well. So I say the 15 Cannons and Mortars supported by a number of weapons from the Engineering college is quite reasonable.
Kinda happy at least one of my initial numbers seemed to be ok.
ConclusionI do agree that it seems ridiculous to assemble an entire State Army, even if the source material provides some numbers and information. There are still many unknown factors.
Maybe lets call it to be the more reasonable army that is assembled and ready at-arms, to march and rally within a weeks notice or so.
I still will have to work out the composition of that army. About 2700 man Infantry + Horse + Artillery and such.
How many would be Spears, Halberds, Crossbows, etc?
Let me see what I can come up. Ok, 2000 miniatures down, some more to go for the first stretch goal.
A man must dream big I guess.
I shall continue to ramble and present further as we go along.