Huge armies are a turn off for me. I switched from 40k to WarmaHordes for that exact reason. Price of minis is kind of an extension of that. For about $100 in WarmaHordes you could probably field a decent army. For $100 in 40k/WHFB, you get a starter pack, which, by itself, is generally not enough to field an army.
Terrain pieces are awesome, if they don't break. Homemade ones usually turn out cheaper, but more fragile. So, I'd pay for quality.
Nope. I played Tau in 40k. Anime Robots, GO!
Or hook up with a budding miniatures company. I can think of one person here in the Playground that is doing just that. Or use Kickstarter.
Also, I'd recommend moving this to the Gaming (Other) forum. You'll probably get a lot more responses there.