> What do you mean by "messed up" ? I've seen a lot a weird things there...

overlapped edges of triangles.  

> I've no experience with Hamapatch though.
> If you mean that the model looks right but that the different parts are
> superposed, there's nothing you can do but exporting and mapping the parts
> separately, using the most appropriate mapping model (box, sphere, cylinder
> etc.) for each part. 

i'm really trying for a solid mesh.  i need to cut a few things out
later.  but if worse comes to worse, i'll rebuild the parts with the
cutouts built in.

> AFAIK, the uvmap size and ratio does not affect the way it's shown on the
> object (the coordinates are not absolute but relative to the map width and
> height). Note that I know this just from observation (I often scale down the
> maps for testing purposes) and the reality could be more complex.
> I hope this helps

me too.

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