well, TS is pretty different, from what I've heard, than Lightwave or max, people love it or hate it, personally I like the interface, and I use only TS6, but many people coming from those other modelling programs usually find it confusing.
Just remember that you can access to hidden tools options with right click on many icons, like for the autofacet angle, and there are other menus that will pop-up only under certain conditions: for example, the point edit tools will pop-up only if you enter in point-edit mode, activating one of the face/edges/vertices selection tools.
The autofacet is in the material editor menu, an icon on the bottom left, but since its position changed in the different versions, I can't tell you its exact position in your version.
Once you activate the material editor menu, the facet/autofacet/smoothing option is one of the small icons on the left. Facet will give no smoothing at all, autofacet will use a defined angle (right click on the icon to change angle) for the smoothing, smoothing doesn't work with PCS.
You will need the version of PCS with custom autofacet angle enabled: it will use the angle you defined in Truespace. check here:
http://www.hard-light.net/forums/index.php/topic,18798.0.htmlabout your model... fso can handle almost any texture size, but as long as it is supported by users' GPUs, and I don't know how many card can use those giant maps.
Also remember (as I said on the other thread) to optimize your model for the game engine: the HT&L system should work faster if if you use as less subobjects possible and as less textures possible on each subobject.
eheh:) the first time I misunderstood you, thinking that the overall resolution of all the textures was 4096x2048, not that EACH texture was of this size....how many textures of them, btw?
well depending by their number, it is probably a bit too much, and you may want to use for example the baking tools of lightwave to reduce the textures without loosing quality, obtaining a better balance between speed and quality