Lego Battlestar Galactica BSG75

A project to build the Battlestar Galactica with Lego

Ein Projekt zum Bau der Battlestar Galactica mit Lego

What we plan to do

This guide describes the process of creating Battlestar Galactica from a pure software model to a real model. You will get an insight into the necessary efforts, the progress, the difficulties that have to be mastered, the limits and last but not least the demand for attention to detail.
Let yourself be carried away by our passion for Battlestar Galactica and follow us in our realization.

Orientaion	Dimension	Picture
Height Width	36,2cm / 14,3 in 61,1 cm / 24,1 in
Length	155,6 cm / 61,3 in

Who we are

We are two normal guys who want to rebuild Battlestar Galactica BSG75 with Lego as a hobby project during our free time. The realization is done parallel to our Work Life Stress as everyone knows it. Because of this reason the project has been going on for a long time.
We are fans of the series. We are excited to create something that is not yet commercially available on the market. We hope to find many people who share our interest and support us in the realization of this project.

From now on our creations will be available under the name KK MOCS.

Contact us

You can find and contact us:

Plattform	Link
Homepage	http://GALACTICA-MODEL.COM
Mail	[e-mail]
Flickr	https://www.flickr.com/people/onthekante
bricksafe	https://bricksafe.com/pages/OnTheEdge/battlestar-galactica-super-scale
Rebrickable	https://rebrickable.com/users/KK_MOCS
YouTube	https://www.youtube.com/watch?v=56g93rVo_WE&ab_channel=ClaudiusKarch

Milestone overview

We developed a plan, structured necessary processes and created milestone steps.

Milestone	Description of the content	Description
MS1	Feasibility	Make the 3D model buildable. Stability test; connectivity test; color availability check of the bricks
MS2	Model optimisation	Stability test; connectivity test; color availability check
MS3	Assembly instructions Build a Prototype Build a 2nd Model	Generation of the construction manual separately for each module Building the BSG Galactica using the construction manual Revision of the manual based on the experience gained from the prototype

Timeline overview

Date	MS	Description
10.2020	MS0	The project: Bring Lego BSG75 to life has started
10.2020	MS1.2	Milestone cockpit successfully finished
11.2020	MS1.4	Milestone arms successfully finished
01.2021	MS1.3 + MS2.5	Milestone middle section + backside successfully finished
01.2021	MS1 Feasibility	Milestone Feasibility successfully finished
02.2021	MS2.1	Milestone Parts optimisation, standardisation, price optimisation successfully finished
05.2021	MS3.1 V1	Basic structure (skeleton) assembly manual process started
05.2021	Supporters	Go live on steam with this guide and some artworks on my profile :
06.2021	MS3.1 V1	Assembly instructions basic structure (skeleton) successfully completed
07.2021	MS3.2 V1	Assembly instructions cockpit successfully completed
07.2021	MS5 + MS3.1 V1	Assembly test of a prototype (V1)
08.2021	MS3.3 V1	Assembly instructions middle section stopped due to model changes after assembly test
08.2021	Backside V2	Assembly instructions backside started, as it was easiest to extract as an module.
09.2021	Backside V2	Assembly instructions backside finished
09.2021	Backside V2	assembly started and successfully completed
10.2021	Cockpit V2	Assembly instructions started and successfully completed
10.2021	Cockpit V2	assembly started
12.2021	Cockpit V2	assembly successfully completed
12.2021	Left + right arm V2	Rework of the two side arms have been started
12.2021	Backside V2	2nd backside assembly started
01.2022	Left + right arm V2	Rework of the two side arms successfully completed
02.2022	Backside V2	2nd assembly successfully completed. Please take a look in the MS3.2 V2 chapter
02.2022	Middle section V2	assembly started
03.2022	Middle section V2	assembly started and successfully completed
04.2022	Left arm V2	prototype assembly instructions started and successfully completed
05.2022	Left arm V2	assembly started and successfully completed
05.2022	Right arm V2	prototype assembly instructions started and successfully completed
05.2022	Cockpit V2	Final assembly instructions started and successfully completed
06.2022	Middle section V2	Final assembly instructions started and successfully completed
06.2022	Right arm V2	assembly started
06.2022	Cockpit + Middle section V2	Bricks for the 2nd assembly ordered (cockpit and middle section)
07 - 09.2022	Cockpit V2	2nd assembly started and successfully completed
10 - 11.2022	Middle section V2	2nd assembly started and successfully completed
12.2022	Left + right arm V2	Bricks for the 2nd assembly ordered (booth arms)
01 - 02.2023	Right arm V2	2nd assembly started and successfully completed
02 - 03.2023	Left arm V2	2nd assembly started and successfully completed
03.2023	Finish

MS1 Ensure parts availability

In this milestone, the model was redesigned to the extent that it contains Lego bricks which are available on the free market in both shape and color.
We have divided the model in a total of 6 sub-modules, which are named as below:

• MS1.1 Basic structure (Skeleton)
  
• MS1.2 Cockpit
  
• MS1.3 Middle Section
  
• MS1.4 Arms
  
• MS1.5 Backside
  
• MS1.6 Stands

MS	Date	Brick Total	Brick Types	Brick Problems	Basic str..	Cockpit	Middle section	Arms	Back...	Stands
Start	10.10.2020	19986	490	910	6647	2945	3091	3845	3082	376
MS1.2	29.10.2020	20372	530	683	6792	3150	3091	3881	3082	376
MS1.4	18.11.2020	20525	525	497	6089	3150	2867	4960	3084	375
MS1.3 + MS1.5	31.01.2021	21072	520	0	6420	3153	2867	4960	3302	370

MS1.2

Before: Coral color = not available bricks

Reworked model:
There is still one weakness which has to be solved during the prototyping in MS5

MS1.3

Before: Coral color = not available bricks

Reworked model

MS1.4

Before: Coral color = not available bricks

Reworked model

MS1.5

Before: Coral color = not available bricks

Reworked model

MS2 Standardisation / Unification

The result from Milestone 1 is a completely feasible model with original Lego parts. Partly not quite matching colors had to be chosen, which was reduced to a minimum. With the help of Bicklink it is possible to use all available parts and colors in the model.

There are different part numbers from Lego for "same" part types. These different types differ only marginally in their function and have no impact on the model.

1. The different part types were standardized to the cheapest version of the available type.
   
2. The model was rebuilt in internal structure with cheaper types of parts
   
3. The model was optimized for the availability of original Lego parts and the cheapest design using the price database of Bricklink

A example of the "same" part types

Panel 4865

Panel 4865b

Fence 30056

Fence 21229

Examples of some revisions:

Original

Reworked

The following result could be achieved

MS	Date	Brick Total	Brick Types	Brick Problems	Basic str..	Cockpit	Middle section	Arms	Back...	Stands	Bricklink Price
MS1 passed	31.01.2021	21072	520	0	6420	3153	2867	4960	3302	370	100%
MS2.1	07.02.2021	21019	436	0	6423	3150	2829	4934	3313	370	50% of the base model

MS3 V1 Prototype

In May 2021 we started to disassemble the model into individual sub-modules in order to generate the construction manual. The instructions will be divided into different assemblies, which are already reflected in the milestones MS1. We are planning the following modules:

During disassembly process the following types of faults can be detected and fixed:

• The connections or stability is not sufficiently guaranteed
  
• The original design can be simplified slightly
  
• Some parts can be replaced by larger designs

This is the reason why the parts list still changes slightly. But not the basic design and dimension.

MS3 Basic structure

The Basic structure (skeleton) contains about 6434 parts in one main layer. These parts have been sensibly divided into smaller groups and put into an assembly sequence.

The Skeleton assembly for the skeleton could be finished and took 50h. The instructions were divided into 9 main steps which extend over 508 assembly pages and 749 work steps.

MS3 Cockpit

The Cockpit contains about 3044 parts in one main layer. These parts have been sensibly divided into smaller groups and put into an assembly sequence.

The assembly for the Cockpit could be finished and took 20h. The instructions were divided into 4 main steps which extend over 219 assembly pages and 441 work steps.

MS3 Middle Section

Aborted see Milestone MS3 Model V2

MS3 V2 Final Model

When we assembled the Prototype V1 in mid-July 2021, we realised that the concept worked.
It has to be turned over and transported several times for further assembly of the outer skin. The transport seemed to be the most critical of all points and so we decided to change the concept by generating several smaller assemblies from one large model.
Currently, this is the biggest change between the V1 and V2 models. Unfortunately, only small parts of the assembly instructions are reusable.

During disassembly process the following types of faults can be detected and fixed:

• The connections or stability is not sufficiently guaranteed
  
• The original design can be simplified slightly
  
• Some parts can be replaced by larger designs

This is the reason why the parts list still changes slightly. But not the basic design and dimension.

MS3 V2 Modul 1 Middle section

A second Middle section was assembled at in autumn 2022 using the instructions. This helps us to identify the remaining "bugs" in the assembly instructions. To carry out minor optimisations to the model that are still necessary.

MS3 V2 Modul 2 Backside

A second Backside was assembled at Christmas 2021 using the instructions. This helps us to identify the remaining "bugs" in the assembly instructions. To carry out minor optimisations to the model that are still necessary.

MS3 V2 Modul 3 Cockpit

A second Cockpit was assembled in summer 2022 using the instructions. This helps us to identify the remaining "bugs" in the assembly instructions. To carry out minor optimisations to the model that are still necessary.

MS3 V2 Modul 4 Left Arm

A second left Arm was assembled in spring 2023 using the instructions. This helps us to identify the remaining "bugs" in the assembly instructions. To carry out minor optimisations to the model that are still necessary.

There is no significant difference between the left and right arms. The photo documentation was made on the right arm. They can be seen in the next chapter.

MS3 V2 Modul 5 Right Arm

A second rigth Arm was assembled in spring 2023 using the instructions. This helps us to identify the remaining "bugs" in the assembly instructions. To carry out minor optimisations to the model that are still necessary.

Pictures of the model

The software can be used to create images that demonstrate the quality of the model.
Here you can get a first impression of how detailed the model is designed.
How complex the basic structure is.
You can imagine how much fun it will be to assemble the model in real life.

The final model:

Front view:

Back view:

Side view:

Top and down view:

Some details:

Inside of the model:

The operating mode:

Thanks

[Exonic]

Unglaubliches Modell, ich würde gern mal mit euch darüber reden.

[Grinsebär]

Hello everyone, we can finally announce that we have finished. Our model has now been built twice. Parts lists are created and the instructions are finalized.

We are always available for questions. Just send us a mail: [e-mail]

Have a look at our homepage. There you can subscribe to the newsletter. HTTP:/GALACTICA-MODEL.COM/

[Arcaine]

Seid ihr echt fertig? Wahnsinn!

[Grinsebär]

Hi zusammen ja heute wurde das zweite Modell fertiggestellt. Nun können die Stücklisten finalisiert werden

[Guyver-666]

seid ihr Fertig ^^
will auch endlich bauen ^^

[Grinsebär]

Hi all, a new update is online. --> Milestone MS3 Model V2 --> MS3.3 Middle section

Please have a look and enjoy the work.

[Arcaine]

can't wait for it

[Dr. PoopFart™]

parts list and instructions are 95% complete

[bobbrockthor7]

curious as to when we will get instructions or even a parts list so i can start getting them

[Grinsebär]

A new update is online. In addition, the chapters have been slightly adapted again. Please have a look and enjoy the work.