...nothing written in stone that says the Leo must be their biggest ship in the fleet. After all, the CRM captured the Dark Shadow (HS:5 freighter) early on in the module so by then they have two ships tied for "biggest".

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There are fifteen total frigates in that roster, seven of which are committed to SpaceFleet. With nearly half the Frontier undefended, Space Fleet is too small of an operation to even consider distinctive classes of warships...the classification here is you are either fortunate enough to have a frigate or you are well versed in waving a white flag.

And fighters.

I house ruled one 6-fighter squadron per population rank (L=1, M=2, and H=3) regardless of fleet or militia presence. An outpost world would be protected by whatever presence is conducting their business there (mega corp, neighboring world, etc).

Armed system ships are another feasible defense for any world (a la Traveller's "System Defense Boats"), more so considering the canon rules permit any system ship up to HS:5 to land in an atmosphere (re: the worlds that lack even an orbital station).

I really like this observation.  We have noted elsewhere the scarcity of starship construction facilities in orbit.  I think it is safe to assume that all medium or higher population worlds have star ports planet side to support repairs of HS 5 and less ships.  Many of these star ports will also have nearby planet side construction facilities for HS 5 and less ships.  We may assume that any heavy population world has a planet side construction facility.  Then we can make logical deductions for worlds with less than a heavy population. 

Thus, if there are 3 manufactures, it is likely that it will average out to a new model every year. Just look at large ship building. They may build just 5-10 ships in a particular model, and then the next order will be a little different. If war is taking place, they may provide as many as 20 ships in a particular model, but not much more. The consumers will always want something more added, or the needs of the times will take precedence.

Yes, unless the point is mass production. Look at WWII - Liberty Ships, Carrier, Destroyers, submarines, etc. 

Liberty Ships for example, Eighteen American shipyards built 2,710 Libertys between 1941 and 1945, easily the largest number of ships produced to a single design. Now, granted the 18 shipyards probably made the ships a little different from one shipyard to another. But still, that's like 100 ships.

With 15-30 ships belted out each year, Space Fleet shouldn't be that small. There aren't even 15 assault scouts listed in the SW2 roster for the UPF, and those are the ships that the UPF has amassed since SW1 (80 year gap if you want to go by the Zeb guideline, and a scout takes 90 days to belt out).

Alas, I too have incorporated jump tugs (an idea I plagiarized from Traveller...they have jump tugs to move their system defense boats around). And yes, any ship that can fit in the hold of a frieghter can be ferried off to other systems as well. I also permit ground based system ship construction/support, up to the canon atmospheric max HS:5 ratings. The difference being an orbital Class3 SCC can service star ships --- meaning they can make berth for repairs (although they're S.O.L. for fuel and engine parts) but the SCC can only construct system ships (of any size). Then again, I also have Shat Rat's Salvage that can ferry parts to any destination so spacers aren't stuck without a paddle in systems without repair facilities. Shat Rat's is able to offer this service due to the uncommon nature of ships...if this was the Star Wars universe, Shat Rat's would have to be a mega-corp just to survive against all the competitors. 

S.S. thank you for that information - I will incorporate some of that into my setting.

KH prominently mentions salvage law on p.43 of the Campaign Book, and that's what gave me the idea of a fully functional salvage business via a "space ship junkyard". A player can, parts availability willing (I whipped up charts for parts availability at any given time), construct a full ship of any type in their station. The station also has numerous shops on the commercial deck offering refurbished items like communications equipment, computers, etc but the big nuts & bolts items like drives, weaponry, hull plating, support beams, workpods etc are in the main "yard". 

The hub is a triple hub, meaning the main hub has additional hubs extending out past the ring on either side. The hub facing away from Evergleem is the docking bay, the center hub contains work bays available for lease for customer projects (players can build a full ship in these bays) along with storage of salvageable hulls that have been collected, and the third hub (facing Evergleem) is the "bone yard" of parts. Being a size III station, anything up to HS:14 can be contained...and their flagship (a size 18 freighter) moored outside the station (requiring interuption of the rotational motion when arriving or departing) is capable of transporting most hulls up to HS:12.

Overhauls can be performed in their docking bay, and they keep a fair supply of fuel on hand that they acquire from contracts with the neighboring SCC. In short, a party can acquire a ship at a small price (compared to buying/building a new one) but the ship will be comprised of predominantly older parts, and each system will have a different chance of breakdown accordingly. As such, Shat Rat ships definitely have their own unique personalities. ;)

The sticky'd threads here offer all the details:

"Fortunately" the spammers keep the ForumUp.org inactive forum auto-prune at bay...so that information isn't going anywhere.

If you include SCCIV, that's an additional 265,000 ships of both kinds but HS5 and below - including Yachts, Privateers and Corvettes.

Places like: Dramune, Cassidine, Truane's Star; can use their SCCIII to make System Ships and use them! They can use freighters, spaceliners, mining ships, AG ships, etc. 

The one thing I do not understand is Clarion having a SCCIII. It should have been a SCCII and Morgaine's World should have a SCCIII. Those System Ships can carry cargo and passengers to Gran Quivera and back.

Below is the HS points, the capacity of each SCC added together for 82 years.

The numbers are from one SCC Station listed/per system, constantly producing.