Hi Mark,
An approach some BBB players use, which might suit your purpose (especially if you're scaling down to 2/3rds as I suggested elsewhere), is:
- don't use one 25x25mm base per base strength of the unit;
- instead, give every infantry unit two larger bases (say between 40x20 and 50x25);
- those two bases let you represent all three possible formations;
- instead of base removal for casualties, use dice or strength counters of some kind to keep track of the unit's strength.
Those larger bases then let you create little dioramas. E.g., you could have one with half a dozen skirmishers, the other with 8 to 12 close-ranked figures and a flag. Etc etc etc.
Chris