Tson (As To answer these Questions...
Tson I think dyson spheres would be useless in combat by the way as the base layer has to be so thin that any shots would tear through it like paper,
This Dyson Sphere is actually Two Half Spheres, Connected together. This allows it to separate and go to different Stars. The Hull Is much thicker than It needs to be, But It has some Aluminium in it, which is a light metal. Although it isn't done yet, Trust me when I say that these have Quite some massive thrusters.
Tson you cannot hope to staff it if it is weaponised, even if you had the population of a whole galaxy you could only hope to man one gun per 60,000, square kilometres, i suggest you change the parameters of your project and either make a ring as i have suggested or you decrease the size of the sphere to non-habitable range, this would mean it would be effectively a giant battlestation like the death star x100
Good Problem to Address. The Staffing thing is um... It's not related to cloning...? I'm being sarcastic, That's the only answer that really makes sense...
Tson unfortunately would also mean that your staff periodically died off due to radiation,
I Had to check the Wiki for this one. Apparently, Aluminium is actually a good Radiation Shield, and separating the Living quarters from the Radiation is The Dyson Sphere's Alloy, Partially made of Aluminium... Not Trying to be a Smart Alec or anything here...
Tson the ten large ships would not even be able to carry enough metal to build a one millionth of the sphere as a whole so i dont know why the work is proceeding so quickly.)
The Ten ships aren't the Only ships Surgeon is Using. They're using tons of them, Trying to set up the back Gate. From there, the Station can be made in seconds, Fabricating material from the star.
Thanks for asking the Questions! Gave me Noodle a good exercise!)