The "full-size" ship exterior set was constructed in a brand-new tank on a beach south of Rosarito, Baja California, Mexico. Construction started on the 85th anniversary of the real Titanic's launch - May 31, 1996 (see also Titanic: Latitudine 41° Nord (1958)). To reduce costs, the number of instances of some repeating sections (such as windows in the middle) was reduced (and later added via CGI), and other parts (such as the funnels and lifeboats) were built at 90% scale to produce the correct visual appearance. The set was oriented to face into the prevailing wind so that the smoke from the funnels would blow the right way. Since the studio was also newly built, sets were often constructed at the same time as the studio building around them. Some of the sets were so big that crew members often got lost in them, necessitating the implementation of a zone system so they could find their way back.

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