ok, here are some more infos:
I have a simple mission with a fighter and 3 of these testing models
model1:
7300 triangles, triangulized model, 150 polygroups (!!!), 4 subobjects, some very minor intersections, one simple 256x256 texture tiled over all the mesh.
the model is loaded fine into techroom, but in the mission after few seconds the game crash and returns to desktop, with no error message.
It is not a table problem (the model is not pofedite, and I tested it replacing the fenris and the myrmiddon, crashing in both cases)
I made a mistake and converted the model without textures. In game you see no models (there is only radar signature and the distance shown in the hud is screwed).
That's strange, I remember that in fs2 you can see untextured models as semitransparent, but I suppose It is HTL related.
BTW, althought nothing was shown, the game crashes as before (it took just little more time to crash).
model2:
it is the same model, but I deleted some submodels.
around 5000 triangles, 75 polymodels, I removed MOST but not all of the intersecting submodels, all those with the worse intersections anyway.
it worked flawlessy.
Now, I have 4 hypotesis
1- the crash was caused by the number of submodels
2-the crash was caused by intersections
3-the crash was caused by something wrong with the specific submodels I deleted
4-the crash was caused by pcount
Considering that I got in the past a 10k poly ship with the worst intersections you can imagine working flawlessy in game, I tend to avoid the second and the fourth hypotesis.
I'll try to restore those submodels, deleting some others: if the game will crash the problem is something related to those submodels, either the intersections or something else, if the game will not crash, it will definitively be something related to the number of submodels you can have, or the number of polys into submodels, or something like that.