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Reading this thread = mind blown at the dedication and perseverance.
When you're watching the show, it's easy enough to just go with the dramatic flow and pretend that, somehow, the internal dimensions of the Eagle fit comfortably within the exterior. (Or vice versa.)
However, over the years, seeing various modellers (both physical and CGI) and blueprint makers* talk of that conundrum, especially as regards the beak, I'm always intrigued to see how people make it work - especially on a project like this.