For one of my MA266(Intermediate 3-D Modeling) projects i deiced i would model a tank or such from the battletech universe, probably a Partisan.
and was wondering whats the low Poly count goal on your vehicle models, what you normally hit on the high poly model.
Thanks~

How are you modelers handling the issue of connecting rounder sections of an object to boxier sections?

Boolean Union/Difference? I find the resulting edge-geometry from this method is often clumsy or asymmetrical.

Are you using NURBS? I should expect not since mechs are not very organic.

I have considered creating 2 separate objects and using the "attach" tool under Edit Poly, and then simply aligning the 2 pieces appropriately.  This of course results in surfaces underneath protruding geometry, but the underlying surface is usually only a single polygon.  Are there rigging/lighting problems with this solution?

Finally, the only other possible I can imagine is to hand adjust/cut/weld all the pieces exactly where you want them, more time consuming, but ultimately the most precise method.  The only problem is a relatively high-poly budget for the flat/boxy surface.

I do whatever needs be done to get the effect I'm going for.
Entirely depends on the model, and the modeler as to which technique suits them best.

I usually start out with a Boxes and Cylinders (basic primitives), then I block out the frame from there attempting to hash out proportion. Detailing usually entails extruding and inserting edge loops where need-be, and from there hand sculpting each vertex into the position I so desire. Everything that will be moving, is a separate piece of geometry. I model things as they would be IRL, and refine after, while keeping my main polycap in mind the whole time. I only add geometry where it needs to be and I never use Smooth Modifiers and I never use Booleans.

I model in Maya tho, so everyone's workflow is different from artist to artist, software to software.

OK, let me reframe my question then.  How would the Catapult's missile pods be attached to the cylinders supporting them in 3ds Max 7, without using Boolean, and without any hidden/inverted faces?

So the missile pods are separate objects altogether?  You simply have them clipping through the cylinders?

There are many ways to cut holes in meshes.
Booleans are just a sloppy shortcut that most of the time require excessive cleanup.

Example of how I went about making some holes for the missiles:

Take a Cube-Shaped Missile Rack for example. Cubes are not very cylindrical so to create a cylindrical surface within a cubed surface I'd extrude the inset face for the racks, then divide that extrusion with edge loops to create enough loops for the holes, then I'd delete the faces for the holes, insert a more loops to create circular definition, then triangulate the edges to keep it clean and low-poly while retaining surface definition.

I'd love to see a quick demo video of that technique.