hi Rexy,
Thanks a lot for shedding light on the mystery.
It's a tremendous relief.
It never occurred to me that the issues were UV related.
This is now my second model for TF2 - well, for any game really ... so it's a learning experience (read:baptism by fire!).
I *think* I follow what your describing as the solution.
Lemme take a stab at it on my own and I'll see how far I get before screaming for help!
Again, thanks for the illumination Rexy!
Cheers,
UGLY