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I could have sworn that upon a time GW made interchangeablekits, meaning things like the Helverins had both the Autocannons and the CC bits, and the Valiant and Castellan models could be assembled from the same box. Apparently this isn't a thing anymore?

It comes down to the sprue layout and design. In the case of the Knights, the sprues were designed so that the Armigers or Dominius class Knights shared some parts, but the unique parts for each build were on different sprues. A similar approach was taken with the Immolator and Exorcist.

There still are new dual kits though - the same kit makes Seraphim and Zephyrim and whichever way you go you'll have a pile of spare bits.

Yeah, I think those are the only Knight kits that aren't interchangeable. The Armigers and Dominus don't come with their other variants' sprues. All the Questoris classes are actually the same, except the Preceptor which has an additional sprue. So a Preceptor box can be anything Questoris, and any other Questoris can be anything but a Preceptor.

There is no other Questoris box anymore, they removed it in favor of only selling the Canis Rex set.

Yea, the "standard" Knights have been through 3 set variants now.

Original kit (Errant, Paladin), then later a 2nd kit that contained the carapace weapons (Warden, Gallant, Crusader), the boxes were priced differently.

The original kit was discontinued, and everything was made from the 2nd kit.

Then came the Canis Rex kit, and the 2nd kit was discontinued, with all Imperial Knights coming from that kit, at a new even higher price.

The Bloodthirster kit builds the three Bloodthirster variants (Insensate Rage, Wrath of Khorne and Unfettered Fury). In order to build Skarbrand, you need a different kit which removes the wings sprue and replaces it with one unique to Skarbrand.

The Leman Russ Battle Tank kit makes the Leman Russ Battle Tank, Eradicator, Exterminator and Vanquisher. The Leman Russ Demolisher kit switches out one of the two sprues and makes the Leman Russ Demolisher, Punisher and Executioner.

The Chimera base sprue can be found in five different Astra Militarum kits.

 carldooley wrote:
I could have sworn that upon a time GW made interchangeablekits, meaning things like the Helverins had both the Autocannons and the CC bits, and the Valiant and Castellan models could be assembled from the same box. Apparently this isn't a thing anymore?

It is really highly variable, probably mostly having to do with space on the frames to allow for duel kits.

The Armigers share 3 different frames, but then have completely separate weapon frames. GW boxes them separately with only the appropriate frames. The Questoris Knights are all mashed together in one box. I'm not sure how the frames work, but the weapons must be on commons sprues so no separate boxes.

Similarly, they were able to jam-pack the Sisters of Battle Battle Sisters box with 10 bodies and ridiculous number of weapons over 3 sprues. It is rather impressive. They then turned around and give the Immolator and Exorist two common sprues plus an individual sprues for their different tops.

 alextroy wrote:

 carldooley wrote:
I could have sworn that upon a time GW made interchangeablekits, meaning things like the Helverins had both the Autocannons and the CC bits, and the Valiant and Castellan models could be assembled from the same box. Apparently this isn't a thing anymore?

It is really highly variable, probably mostly having to do with space on the frames to allow for duel kits.

The Armigers share 3 different frames, but then have completely separate weapon frames. GW boxes them separately with only the appropriate frames. The Questoris Knights are all mashed together in one box. I'm not sure how the frames work, but the weapons must be on commons sprues so no separate boxes.

The Questoris are designed with three main sprues containing the body, shoulder Stubber, RFBC, Reaper, and Thermal Cannon. There are main body components on the sprue with those weapons. They then added a 4th sprue with the Fist, Avenger, shoulder melta, and all 3 Carapace weapons. The latest version added a 5th sprue with the Las-Impulser, shoulder Multilaser, and the Canis Rex specific parts(including cockpit and foot version of Sir Hector). You require parts from all 5 to make Canis Rex, so there's no reason to do separate kits.

There is a reason to not include the Canis Rex sprue (a cheaper 4 sprue box that creates everything but a Knight Preceptor/Canis Rex). Still, it is equally valid for GW to just toss them all in the one box and have just one Knight kit to rule them all.