I'd like to modify Mushroomhermit's idea a bit. Let's still tightly restrict the ranges in which a given material can drop, but make weapons vary much more in quality in that range. We'll justify this by adding multiple designs of a given weapon type. For example, take the one-handed blunt weapon type. Make a number of weapon designs within that type: cudgel, mace, flail, warhammer, and flanged mace (in ascending order of power). For the first ten levels or so of the game, you'll only be seeing iron and the occasional steel weapon, but you'll be able to upgrade appreciably without even seeing additional materials, say from a cudgel to a flanged mace.
The best weapon design of one material will actually be better than the weaker weapon designs of the next material. For example, a steel flanged mace would be better than a dwarven steel cudgel and a dwarven steel mace. Here's a sample table of average physical powers for weapons of the various materials. Note that galvorn and mithril have been replaced with voratun and stralite, respectively. (If you have cooler sounding names, let's hear them! This was the best we could come up with on IRC on short notice.)
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Weapon Average physical power
Iron cudgel 5
Iron mace 8
Iron flail 11
Iron warhammer 14
Iron flanged mace 18
Steel cudgel 13
Steel mace 16
Steel flail 19
Steel warhammer 22
Steel flanged mace 26
Dwarven steel cudgel 21
Dwarven steel mace 24
Dwarven steel flail 27
Dwarven steel warhammer 30
Dwarven steel flanged mace 34
Voratun cudgel 29
Voratun mace 32
Voratun flail 35
Voratun warhammer 38
Voratun flanged mace 42
Stralite cudgel 37
Stralite mace 40
Stralite flail 43
Stralite warhammer 46
Stralite flanged mace 50
Another problem I'd like to solve is the problem of homogeneous gear materials in the endgame. Clearing out a pride at level 48 results in a dungeon carpeted in mithril. Let's see some more variation! To this end I propose several special materials on par with stralite that have a level range somewhat beyond it, and thus show up more rarely. Some special materials are rarer than others. These materials have special properties and restrictions. For anybody wanting to suggest new special materials, try to give it a mechanic that justifies a whole new material rather than just an ego. A special fire-resistant metal is not very interesting, for example.
Here's what I have so far for special endgame materials:
Mithril
Lower encumbrance on all equipment. Lower fatigue on armor. Higher attack and higher crit on weapons. Never used for blunt weapons.
Adamantite
Higher encumbrance on all equipment. Higher armor values and fatigue on armor. Higher APR and physical power on weapons.
Etherealite
Massless, but all magic and stuff. Zero encumbrance on all equipment. Zero armor value and defense value on armor. Zero physical power on weapons. Etherealite equipment is always generated with double egos, and all ego properties are boosted by 100%. Etherealite melee weapons always have one of the melee_project egos for a prefix. They do no physical damage, but still deal their melee_project damage, which is boosted by 100% like all other ego properties. Doubled resists on Etherealite body armor could be super unbalancing, so we'll probably need to do something about that. Etherealite could be included in non-metal lists of special materials, too. Etherealite mage staff? Cool. Etherealite bows might be weird, though.
Lifeiron
A metal that miraculously learns. A lifeiron weapon is a sort of lite version of the sentient weapons described here. It has a talent tree and gains levels and talent points like the wielder. The player can spend the talent points as he sees fit. Possible talent tree:
Lifeiron weapon (mastery 1.00)
Improved attack 0/10
Improved APR 0/10
Improved crit 0/5
Improved ego 0/5
As with sentient items in the linked post, Lifeiron weapons have a maximum level. You won't be able to max all of their talents, so lifeiron weapons should end up looking different for different characters. Lifeiron armor would work in a similar fashion. Should be fun!
Obviously I've neglected things like nonmetals and nonmaces, but the ideas are applicable everywhere. Let's hear some similar ideas for bows and staves and slings and daggers! And how about some special woods and fabrics to go with the special metals above?