As I had stated elsewhere, there are over 1100 parts in the MR Falcon. Think about how many individual parts ONE THOUSAND, ONE HUNDRED is.
Take that in.....
If I had to build one, I would look at the box of parts and jump out the window. :lol MR had to make it that many parts, so that we could capture all of the undercuts and deal with the various properties of the different materials (resin/inj ABS, Inj PVC, etc...)
I built a Tamiya 1/32nd F-16 and that had about 600 parts...and it still took me a year to finish. And I had a huge instruction booklet to guide me.
Obviously, if you are making a Falcon kit, you can combine assemblies to save casting work and lower the parts-count. But the castings are so large, that they have to be "beefy" or they would crack and/or deform under their own weight.
I HAVE to ask though...
Over the last year, there has been a price dip for the Falcons here and on eBay. Why would you want to build a thousand pieces, when you could have a pre-built model for less???
Yes, the paintjobs were "variable", so do what I did and REPAINT it. It took me about 60 hours but it was definitely worth it.
On the weight thing...we were ALWAYS concerned about weight. The MR model is a hollow resin shell over an aluminum armature and it is STILL 50+ pounds. If you think you are going to have a SS Falcon in resin and have it light weight, forget it.
A team of engineers and designers spent 18 months trying to accomplish that and we couldn't do it. Now, if you substitute a lighter resin for the Polystone (which we HAD to use, no choice from the factory), that will cut maybe 5 pounds. But you are STILL at 40+ pounds!
The only way to have it notably lighter is to make it from plastic sheet like all of the scratchbuilders do.
If you hate the MR base, just ditch it and make a new one!
Frank. I think you are walking dangerous ground here, amigo. You will spend an enormous of time making kits for 5 or 6 people who actually follow through and pay. That is a terrifying amount of work for what you are talking about charging.
Look...I am selling Aliens Grenades and I am having a bunch of people flake on me and these are $20!!!
$1800? Go with God...
(And let me know when you come out with a CARBON FIBER Falcon kit.
I will buy TWO!) :lol