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I've built a few custom Settlers/Seafarers sets, from a range of materials. I went the whole clay model / latex mold route. Then I built a set with hand-painted wooden pieces, with laser-cut hexes and of course custom artwork.
The current set is much more ambitious: an actual table, with wrought-iron legs, and a large, rotating top with the Catan tiles being actual porcelain tiles, giving the table a mosaic effect.
It's a nice, non-electronic hobby.
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