The general philosophy is that these ships need to look good. I mean
good. This game is gonna be sexy. Since in space, all you have to look at is other ships, we have no reason not to have absolutely gorgeous models. The more references there are for a ship, the more it needs to look like those references. Any other ships that have only been invisioned in crude comic drawings and other games have more liberty given to the modeler as far as what it should look like.
Normal maps: Currently not a stable feature, and even in 3.6.10 they'll require a very high end card to use them (Shader Model 3.0 is needed, even recent midrange cards aren't always compliant, only 2.0 typically). So, the more we can do without, the better. They'll be able to save us time creating the massive tiny greebles and fine details on a lot of ships, but really solid detail would probably be better on the mesh. This has been the plan from the start essentially, as we've known about normals coming for quite some time. Some of the really fine details on the ships may be used to generate normal/parallax maps, but for now we're just putting most detail in the mesh.
Cockpits that are seen from outside the ship will be modeled for all fighters, and possibly other ship types as well (bridges, anyone?). The virtual cockpits will hopefully be able to be separate POFs in the near future, and save us the trouble of having to create those right now.
Detail boxes will see lots of use for the capital ships and other large structures. We don't have an established set of guidelines for them, other than if you use them, use them right
Brand or Turambar will have to answer any Max questions. But FS units are in Meters, it's just that I don't know how well the max pof exporter maintains units, and how well any other conversion steps treat them. I'm pretty sure we've had a lot of luck with unit conversion with the exporter though.