I suspect without ISRU production of bulk orbit sheet metal, the most feasible solution is to repurpose rockets in their whole.
Building a station this large is gonna be costly even within the cargo hold of starship. But six of them, gutted of insides as welded end to end could provide the vast majority of the bulk mass.
This assume rather sophisticated orbital welding and object manipulation; but its feasible we could do it with robots.
Building a station this large is gonna be costly even within the cargo hold of starship. But six of them, gutted of insides as welded end to end could provide the vast majority of the bulk mass.
This assume rather sophisticated orbital welding and object manipulation; but its feasible we could do it with robots.