I hate posting these tangents in your thread, but I think I might have hit on something.
A lot of the models I convert come from various sources way outside the FS2 community, people just make models differently and not for our specs, I just get permission to try a conversion, 99% of the time the original modler isn't involved after that, just me.
Anyway Cobra suggested Gluing lights to all the submodels (and some of these have dozens, forget that!)...BUT I just noticed something.
I am currently working on a new Romulan TMP era vessel and am in the process of knocking off a few dozen textures (60 to 49 to 23) and in the final stages to get to 15 textures (I use the 16th as a temp slot to later turn into invisible for Trek style hull texture turrets).
In this process I make .cobs and turn them into .pofs to get all the common slots that use the same texture to become ONE slot. Then take the pof, examine what I can combine to trim off or alter and go back to .cob for editing...
LONG story short I only do this with basically KA models as it's required. BUT I do remember they also are made up of many "loose" subobjects, but after making a .pof back into a .cob they all are merged into the hull and it becomes a "Freespace2 Model"... I just loaded it up in TS and it is one object now (called Object 1)
Do you think I need to simply strip off all the turrets I added, reconvert it like it was before. and THEN make the pof back into a cob so all the "loose" subobjects are merged and then re-arm it?
Will that solve the mysterious: "Too many chunks" error? (I still don't know what that means)

Either I'm just stupid, or an unrecognized genius...
