For me that's a perfect shuttle. Good work on this fighter so far. Had to say this<;, though I can't help you 
Thanks

It's still far away from completed though.
whit i do in a situation like this is grab all your shield verts and hit weld (be sure your threshold is low enough). thin make sure the mesh is triangulated. if all else fails, get it into truespace glue it to a cube and run that through pcs2. then import it into your model with the good geometry. might also be something to do with the shield collision chunk, which is fairly new. but from your first image it seems a couple of those polies are being uncooperative.
Well it's a standard 3ds max geosphere but I tried welding anyway. No effect. Not completely sure on the triangulated part.
Whats this shield collision chunk you speak of?
Just to note that the few faces that are lit up in the first screenie in pcs2 seem to be a basic lighting effect that just rotates along.
Results I had so far: 'Normal' shield mesh doesn't stop any hit thats directed at the hull. Just shows up when shots are near misses
'flipped normals' shield mesh (yeah I said the flipping crashed the exporter, I was just doing it wrong) only stops shots coming from the front, back and sides but refuses duty when it comes to shots coming from up and below.