I'm making steady progress on the 'flat' hills. I've done the first two lots of 3" wide hills and am in the process of gluing the flocked paper onto the next set of two 4" side hills.
This is the process I've been following. I mark out the shapes required on 12" square mdf (6mm deep). These all finish at set widths (2", 3" and 4") and so will fit easily together. I then cut them with a jig saw.
I then overlay the cut MDF onto the back of the flocked paper and mark the conours - then cut with a knife. Then I PVA the MDF and glue the cut shape to the requisite piece of cut MDF. Then just apply pressure (lay something heavy over the top) and leave for an hour or so.
Then trim any excess paper (there shouldn't be much!) and then stack them as required.
In the above pic you can see two straight edged pieces. Put these together (straight edges meeting in the middle) to form a ridge or base of a hill 6" wide.
Then place a further 3" wide piece on top to make your hill OR to make your ridge higher.
The pieces in use. The two straight edged pieces have been joined together to make a gentle hill (with the Romans clearly on the hill and the Gauls not on the hill - so the Romans have the advantage.
Now with the extra 3" piece added, it makes a steep hill. Both units are on the hill but its clearer now who holds the advantage (the Romans at the crest, the Gauls lower down) so the Romans still hold the upper hand.
Note that all units sit nicely on the piece without slipping off (as we've experienced with sloped hills). But its the modular effect I'm really happy with. We play Napoleonic rules as well as ancients and often re-fight historical battles. Trying to replicate the terrain in the past has been troublesome, but with this system it will be a piece of cake. The same should apply to historical battles and provide more flexibility and realism for future battles.
So the items can easily fit together to form a different terrain feature - such as a raised plateau or a gully / long ridge etc.
A raised plateau! Just happens to be square but you can barely make out the joins. Barely.