the reason I move 20,000 men to the New World is because colonial nation AI is idiotic and natives spawn thousands of troops to siege all my things all the time.
I think extra maintenance for oversea units depending on the oversea regiment / transport ratio would be fine. The transports should be very expensive in maintenance too. Of course a country with a lot of overseas units would weak the rest of the navy and pay enormous sums to supply the units, especially if the supply chains are overextended (buying from neutral smugglers etc.). There could also be events/ideas etc to modify this ratio. (disovery of america, england)
Also on other continents there could be only cheap colonial units recruitable, which could work like mercs with lower pips. So europeans would use some expensive but stronger european units and a lot of weaker (compareable to the surrounding units) but cheap colonial units in the colonies. perhaps this colonial units could have an own forcelimit, depending on cns + tcs + oversea colonies bt/development. Also there could be events/ideas to change fl, costs etc.
There wouldnt be unrealstic amounts of european soldiers all over the world, but a small force in every region supported by colonial armys if needed.
I haven't read most of the thread (for which I apologize), but thinking about this, I wonder if a decent solution (and one that could actually be implemented relatively easily, I think) would be to just increase the rate of attrition ticks on armies aboard transport ships. Combined with no replenishment of armies during transport, this would cause armies to arrive after long voyages in a much more depleted state. This would mean, for example, a British army sent from the Isles to India would arrive with a decent hit to his troop count (and a notably larger hit than say, the same army moving from the Isles to Gibraltar). This would cause such transfers of armies to be a bigger issue manpower wise and cost-wise (due to the reinforcement cost). Would probably take some work to figure out the appropriate number of attrition ticks to get a result that is a decent mix of historical and good for gameplay.
More elaborate changes would probably be for the better, but are much harder to actually implement in a way that adds to the fun of the game, doesn't break the A.I even more than this simple change would, never mind the actual difficulty of coding such a system.
Would probably take some work to figure out the appropriate number of attrition ticks to get a result that is a decent mix of historical and good for gameplay.
More elaborate changes would probably be for the better, but are much harder to actually implement in a way that adds to the fun of the game, doesn't break the A.I even more than this simple change would, never mind the actual difficulty of coding such a system.
The question is whether your proposed change would meaningfully improve game play. I don't see how it would, and because the AI is notoriously bad at handling attrition, your proposed change is likely to have all sorts of unforeseen complications.
That's the bottom line with this thread and so many others. EU4 is a war game with an emphasis on historical flavor, but it is a game, first and foremost -- a heavily abstracted and oversimplified game, by design.
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Any pro-realism argument or suggestion must be tethered to a clear understanding of how it relates to the game play experience, else you're left with an ever-receding goal and a hopelessly overcomplicated game. Accept that a regiment needn't necessarily represent 1,000 soldiers in all contexts; accept that a single cog doesn't literally carry 1,000 soldiers or that a single boat probably isn't blocking the strait of gibraltar. You'll enjoy the game more that way.
Can't really say about overland but for overseas, I see two possible solutions (or both of them can be used):
1.) Make transport ships its own force limit separate from naval force limit and impose very low base for it, to be slowly increased over time, making it harder to raise large transport fleet without cost penalty.
2.) Increase cost for transport ships to make them more expensive to build and maintain than even ships of the line.
These are not perfect nor the last one may be historically plausible but I think these may help make transporting large armies overseas pretty difficult and more expensive.
Even in Europe power concentration is a huge problem. France shouldn't be able to commit 95% of their army to invade an OPM. Even if they do, other neighbors should take advantage of undefended borders of France.
A previous poster made the point that Europeans did not take down overseas empires single-handed; like Cortez (or the British in India) they allied with local forces, using the locals for bulk and their own troops as a high-quality core. That's exactly right, and most European powers were reluctant to arm and train the natives because they knew who the next target would be.