by Sarah Herman
One of the more popular Technic sets from this period—the Backhoe Grader (8862), released in 1989. © David Martin
With the unprecedented success of the new minifigures and Space System, the LEGO Group was ready to reward loyal fans with a brand-new theme. Jens Nygaard Knudsen was promoted to head of design in 1978 and put in charge of developing themes that were both futuristic and historical. After giving children the sci-fi play environment of Space, his department decided to concentrate its efforts on the past and a truly regal theme. Before the launch of the first Classic Space toys in 1978 and 1979, the LEGO Group had touched on the theme in earlier sets to gauge its popularity and success, as well as to develop building methods and styles for this new scientific frontier. The medieval world of LEGO Castle—one of the longest-running and consistently popular LEGO themes—was introduced in a similar way in 1978, with the release of a set simply named “Castle.” Known to Castle collectors by its product number “375”—which indicates its categorization as a larger Town set, as opposed to a new theme—this three-turreted, bright yellow design featured a great variety of bricks to create the various slopes and walls, a drawbridge, a sticker sheet to decorate flags, shields and torsos with the Heraldic designs, as well as a record fourteen minifigures. This delightful set was one of the first to take LEGO building to another time period, and the addition of these knights and guards, with their helmets, horses, and weaponry, transported the castle model from historical relic to a living, breathing battlement.
Although 375 was the first castle set children were able to buy, it wasn’t the first time the LEGO Group had encouraged them to build castles. Eighteen years previously, the first major LEGO Idea Book was released, emphasizing to children that they could build more than what was on the front of a set’s box. Some of the larger illustrated models shown were actually produced by the professional model shops in Billund, Wrexham (U.K.), and Detroit (U.S.), to be bought and displayed by retailers. Of course, many children didn’t own enough bricks to build the large designs, but it was something to aspire to; the idea being that if they kept collecting LEGO bricks they might be able to build what they saw—such as the blue and red five-story castle in the 1960–1963 Idea Book. Although the set itself wasn’t sold, and the book featured ideas as opposed to detailed instructions, the spare parts packs sold through retailers meant they could potentially purchase all the bricks required to re-create a similar castle of their own. Other glued-together castle models were also sold through retailer magazines for display purposes, and some were built exclusively for advertisements and catalog photographs.
One of the most highly prized LEGO Castle sets is this yellow stronghold (375), released in 1978. © Owen J. Weber
In 1979 two more castle-related sets were released, signaling a move toward the new theme. They were Knight’s Tournament (383)—a small jousting set that included some rare parts (a large tree, two red decorated flags, and a female minifigure)—and Knight’s Procession (677), a set of six knight minifigures and a small cart. The bright colors and harmless activities depicted in these three sets created a romantic, positive image commonly associated with the chivalry of the era. In the same way early Moon-landing Space sets were eventually replaced by space-cruising bad guys and police units, later Castle sets would feature more realistic colors and create factions, pitting knights (and other creatures) against each other in battle, making these early sets particularly unique.
As part of the theme’s development, one of Knudsen’s colleagues was charged with designing a horse figure for the theme (previously the horses had been built from an assortment of bricks). “After several handmade samples, we approved the horse with the design it still has today,” Knudsen said. The theme’s historical period required new levels of creativity, pushing designers to come up with all the elements required to create the medieval aesthetic, Knudsen explained: “We developed new accessories for the minifigure, such as helmets, visors, shields, swords, and flags, as well as developing new decorations and a (Tudor-style) wall element. We introduced grey bricks for this theme. Later we would go on to design a sorcerer, ghosts, skeletons, and an impressive dragon.”
Maintaining fan interest in a theme that has run as long as Castle relies heavily on reinvention and the introduction of new factions. While the earliest LEGO guards from the first Castle set wore a blue and purple uniform with the crown on their torsos, other knights from the same set wearing different colors were also represented. It was not specified as to who the knights were, or whether they were on the same side. The release of a group of Castle sets under the LEGOLAND banner in 1984 saw the emergence of two distinct groups of knights. With more specific names attributed to sets and castles, and with identifiable uniforms and flags, it became commonplace for fans and LEGO literature to refer to these groups by name. Here, we explore the sub-themes of “Castle” released during the 1980s, their identifiable crests and clothing, and some of the sets in which they feature prominently. The date in brackets indicates the time period that each sub-theme was available.
WEETABIX CASTLE
Before 375, in 1970, British cereal eaters had the opportunity to own the first-ever LEGO castle set. In exchange for Weetabix box coupons, LEGO fans could send off for a 471-piece castle. Although smaller than minifigure scale and not as uniformed as its yellow ancestor—it included gray base plates, white turrets, a yellow corner tower, red walls, and blue finishes— it introduced the idea of using sloped bricks at the base of towers and 1 × 2 bricks to create the battlements. Due to its limited availability and its place in LEGO Castle history, this set is highly sought after by collectors.
A massed army of Black Falcons show off their blue uniforms with black and silver design. Collectors regularly trade minifigures from this era as they are no longer in production. © Ruben Salanda
Black Falcons (1984–1992)
Of the earliest sets released, the predominant shield design was that of a bird on a black and white crest. Although never officially named in LEGO literature, their 1986 castle, Black Falcon’s Fortress, and this crest are the reasons fans have given them the moniker. This castle, encouraged by fan support, was re-released in 2002 as part of the LEGO Legends series. The majority of sets were sold until the early 1990s, and the last new set to feature a Black Falcon crest was a 1992 Black Knights set, the box of which happened to feature two Black Falcon minifigures with their swords raised—indicating that the two factions were enemies.
Crest: A black and silver bird (presumably a falcon) spread-eagled on a contrasting black and silver background.
Dress code: Their crest appeared on a blue torso, while their arms and legs were usually black. Some knights wore (painted/stickered) silver breast plates, and had black or gray helmets with slotted visors and colored plumes.
Find them: At home in Knight’s Castle (6073), fighting off the Crusaders in Battering Ram (6062), and manning the catapult in 6030.
Crusaders (1984–1992)
The same year the Black Falcons saddled up and rode out, the King’s Castle appeared, adorned with the image of a lion, protected by red and blue knights and guards. Some of the sets from this era including King’s Castle (6080) feature guards with a crest of two crossing axes, as well as those wearing the lion crest, working together, and these are often referred to as Lion Knights sets. In 1992 LEGO referred to the lion-wearing “Crusaders” by name, but officially only a few LEGO sets from 1990–1992, including King’s Mountain Fortress (6081), are considered “Crusaders.” Given the similar appearance of the earlier sets, it’s common for people to consider all the lion-crested sets as Crusaders.
Crest: Either a blue lion on a yellow background with a red border, or a yellow lion on a blue background with a red border.
Dress code: Red and blue are predominant with the ax-crested minifigures wearing red torsos with blue arms and legs, and their lion-crested friends wearing red torsos and legs (sometimes gray) with blue arms. Painted/stickered silver breastplates were
worn by some, while others were decorated with chain mail. Later Crusaders usually had black legs. The Crusaders in King’s Mountain Fortress were the first to try out the new knight’s full face helmets more commonly worn during the Crusades.
The impressive King’s Castle (6080) in gray bricks could be opened out, as shown, to create a formidable defensive line against their enemies. © Owen J. Weber
An armor-clad Crusader brandishes his LEGO sword and shield—just some of the many accessories the LEGO Group designed to bring this medieval theme to life. © Jordan Schwartz
This simple civilian setting (Guarded Inn) is one of the most popular LEGO Castle sets of all time, and was re-released in 2001 as part of the LEGO Legends series. © David Martin
Find them: Haunted by one of the first glow-in-the-dark ghosts in King’s Mountain Fortress, protecting a maiden in Guarded Inn (6067/10000) and rowing a boat in Viking Voyager (6049).
Forestmen (1987–1990)
While previously focusing on the pomp and privileged of the knight class, the LEGO Group turned to the outlaws of medieval times with the introduction of Camouflaged Outpost (6066) in 1987. This set was the first to feature the Forestmen—a group of merry bandits who lived in tree-covered caves and castle ruins. In some countries, the Forestmen were directly associated with the legend of Robin Hood— with 6054 (otherwise known as Forestmen’s Hideout) referred to in some territories as Robin Hood’s Tree Hideaway. They fought mainly with brown bows and arrows and the odd sword or wooden spear and while not technically a “Castle” subtheme, they could be seen launching an attack on the Black Knights and the Black Falcons in the 1989 catalog.
Crest: Not all the Forestmen were lucky enough to be carrying shields—but some of their bases proudly displayed the crest of a noble stag on a green background with a brown border.
The Forestmen brought vegetation to LEGO System in a big way, especially with this hideout set, Camouflaged Outpost. © David Martin
Dress code: The most common Forestmen minifigure, was the “Robin Hood” of the pack. His green torso and legs with red tunic and brown/green hat with a red feather make him unmistakable as the legendary folklore figure. Variations on the same outfit with blue, gray and black tunics made up the rest of the bandits, including a female minifigure with green bodice and necklace (only available in set 6071).
Find them: Hiding stolen treasure in Camouflaged Outpost, battling a lone Crusader in Forestmen’s River Fortress (6077), or keeping lookout from the rope bridge in Forestmen’s Crossing (6071).
Black Knights (1988–1994)
Although not strictly referred to as a “Black Knights” set, Black Monarch’s Castle (known in the U.K. as Black Fortress—not to be confused with the Falcons’ 6074) was the first set to feature knights holding the Black Knights’ shield. The castle was essentially a black revamp of King’s Castle with octagonal turrets, but was capable of being hinged open to attach smaller sets and build up a larger structure. The move from building gray castles to introducing the distinctive black structures is something designer Jens Nygaard Knudsen remembers well. “We kind of liked it, but it didn’t please GKC (Godtfred),” he recalled. “Maybe it brought back memories he had from the War, I don’t know. It did take us a long time to convince him, though, and prove that the black castle brought a dramatic aspect to the theme—not an evil aspect.”
In 1992 that drama was embodied by Black Knight’s Castle, perching atop a rocky hill with drawbridge and Tudor-style wall piece. The sub-theme was official, and the knights had even more to contend with, fighting off the Forestmen. The Black Knights were included in new sets until 1993, and were replaced by the Royal Knights in 1995.
Crest: Sets released prior to 1992/1993 usually featured smaller shields, the same shape as previous sub-themes’, with a yellow and blue dragon on a red background with a blue border. Marking the official launch of the Black Knights in 1992, a new oval-shaped shield was introduced and the dragon design was changed, including the color arrangement—it was now a blue and red dragon with a yellow background and blue border. The Sea Serpent (6057) flies a sail with a red dragon design on it, too.
Dress code: An official Black Knight, as seen in 6009, wore all black with a red belt and gray detachable breastplate. His helmet was a new design for LEGO with an intimidating black visor, capable of attaching new dragon-style plumes to the top, and plumes to the side as well. This knight donned a wispy red mustache and beard. The Black Knights were the first Castle sub-themes to have minifigures with facial hair.
Find them: Rowing a boat under the watchful eye (and crossbow) of a Black Falcon in Battle Dragon (6018), preparing for catapult fire in Knight’s Stronghold (6059), and getting spooked by Black Monarch’s Ghost (6034).
By the late 1980s, business was booming. The LEGO Group had been inventive and selective enough with its new product lines to increase sales, despite the changing toy climate. They had developed a wide fan base who excitedly picked up each new LEGO catalog to discover what new products were going to be reaching a toy shop near them soon. For the true LEGO fan, there was the option to be a member of a LEGO Club—such as LEGO U.K.’s LEGO Builder’s Club, which started releasing a eight-page magazine Bricks ’n Pieces in 1981 (the magazine had been going in a smaller newsletter format since 1974). In 1988 a LEGO U.K. catalog advertised that in exchange for a £2.95 check postal order, lucky British LEGO fans could receive a LEGO Club badge, a membership card, a sew-on patch, LEGO Club stickers, and three copies of the magazine. By joining you also had the opportunity to enter LEGO Club competitions and receive special offers.
This was not a new concept—A. C. Gilbert had encouraged Erector fans to sell subscriptions and submit ideas to Erector Tips magazine to earn the title of “Master Engineer,” while Frank Hornby’s Meccano Magazine was originally distributed free to fans. Before the age of the Internet, fan clubs were the way children communicated with a company or product, interacted with other fans of LEGO toys, and felt like they were part of something special. For a toy manufacturer releasing new products twice a year, the LEGO magazines served as both a platform to encourage creativity and community and as an advertisement for new sets. The LEGO Club today still offers a free magazine to kids (as well as a junior version for builders under seven) and also includes online material such as videos, building tips, and competitions. Despite Bricks ’n Pieces running LEGO building competitions in its pages throughout the 1980s, the wider LEGO community had its first opportunity to come together in 1988 at the first LEGO World Cup competition held in Billund, where fourteen countries were represented by nearly forty children.
The 1980s saw LEGO tackle fantasy worlds and technical building and introduce niche ranges like FABULAND with great success. The development of Space and Castle themes proved LEGO’s versatility as a toy capable of portraying vastly different environments. The idea that if you could imagine it in LEGO bricks, you could build it from LEGO bricks was starting to take hold, and as the company and its minifigures turned the corner into the next decade, it seemed that with LEGO toys anything was possible.
Making LEGO
Although LEGO will always be a Danish toy from a Danish family, its appeal is nothing short of universal. Early on in the company’s history, local sales offices were established all over the world and with LEGO products being shipped to more and more countries, it wasn’t long before the production of LEGO toys went global, too. Surprising to some, the main LEGO headquarters and one of its factories are still in Billund, Denmark, where the whole story began, although the production facilities and processes have changed significantly since the first LEGO bricks were made.
Rapid expansion, universal customers, and dramatic changes in the world’s economy have had an immediate impact on the production locations of not only LEGO, but the entire toy industry. In 2007, 60 percent of the world’s toys were made in China, which means LEGO remains one of the few large toy manufacturers still producing toys outside of Asia. But Billund is not the only
place proud to manufacture LEGO parts. Over the last fifty years, plants have existed in South Korea, Brazil, Switzerland, Germany, and the United States. In 2000, after thirty-five years of production and distribution, it was announced that the Enfield plant in Connecticut would be closed and the warehouse and packing responsibilities moved to Mexico. A large proportion of domestic production in Billund was also moved to the Czech Republic where costs are lower, while the manufacturing of LEGO Technic and BIONICLE products was retained in Denmark. In 2006 production was contracted out to Flextronics, a Singapore-based company with facilities in Eastern Europe and Mexico. The plan was to retain the production of specialized and highly technical products (such as Technic and BIONICLE) in Billund, while the production of more wage-intensive, voluminous System products would be outsourced to lower wage-paying areas. This restructuring aimed to secure LEGO’s financial position in the toy market after reporting its first deficit in 1998, and then facing tough competition from cheaper rivals, such as the Canadian-based Mega Bloks. But after three years of working with Flextronics, LEGO ended the contract, regaining control of production. Stating that after a successful run with Flextronics, they felt LEGO was better off handling global manufacturing itself, rather than outsourcing, they relocated the Mexican plant from Juarez to Monterrey (also in Mexico) and negotiated with Flextronics to take over its Hungarian plant. Today, the LEGO group also retains sites in Kladno, Czech Republic, and works with other manufacturers in Hungary, Poland, and China.
