AHH!!!! my apologies, I am jumping the gun a bit. I was assuming you were doing all the calculations in the one go. The normals and normalizing them to unity.
Oh okay, that makes sense

I am just trusting the existing normal values in the models for now. This seems to be a reasonable assumption to make, except for elements that are parts of moving parts - I think they have correct normals, but the constant "D" part is wrong. Is this something that has been observed in EAW? Is this related to:
I attempted to get the R/S to work on the wing but due to limitation in the R/S program it was very time consuming. For one thing you have to remove all the inserts for the landing gear and then move the gear to a "neutral location" before even trying to get a working R/S. When and if you do get an R/S you then have to move the gear back to it's correct location. ( Quite a PITA.)
Are the constant "D" parts of the normals calculated as if the moving part's origin was (0, 0, 0) or something?
As for the argument:
If one uses a structured approach and some planning, it is not even necessary to test for working BSP until major parts of the model are done, or until the whole model is done. One only has to understand how BSP works and build the model in a BSP compliant manner. One should be able to build their new model and write out manually the BSP(RS) sequence as they are creating the model without even using a BSP(RS) tool. This is where bulkheads become a very valuable tool.
I think that sydbod's approach sounds possible - I
think I could make a model that way - but I can imagine an easier way...
After every 5 or so added elements you have to leave the 3dz program and run the R/S program or you run the risk of making a model that doesn't pass the R/S and you have to tear it apart to find the offending element.
I think the below would address this:
The one thing we desperatly need in an updated studio is making a new RS every time the model is altered, and if the RS can't work, then an on screen warning should be seen, as well as a warning for twisted elements.
I was going to say the same thing myself! In terms of getting a warning when the RS tree can't be generated, I guess we might define "failure" as the tree generation running for more than a few seconds. The warning should probably indicate what element you added to trigger the RS tree generation failure, just in case you've added another element since then, but I gather the user interface probably doesn't enable you to add elements very quickly?
I can't imagine it would be very hard to add this to the current 3DZ Studio - you can just save a temporary .3dz file after every element addition and call the RS tree generator in the background. 3DZ Studio can kill the RS tree generator if it runs for too long and delete any huge log files it may have generated.
Also:
Ah, there's some important things that Will's version does better.
1 - Adding piggybacks with new nodes. I know, we shouldn't be using piggybacks but they still have a place when upgrading old models.
So a piggyback can't be a separate element referencing the
same nodes?
3 - Color notification if an element has piggybacks.
How is this done, just by highlighting any element for which there is some other element with the same shape and node locations? Or is there explicit tracking of the piggybacking somewhere?
I suppose I also have a dislike for VisualBasic based programs, as I am a little too old to start to get good proficiency in that language. This dog has become too old to want to learn new tricks .... I have become a grumpy old fart.
I'm not sure that that is a good reason to dislike VB. I, on the other hand, used it for years before I learned some better languages, so I think I am fully qualified to dislike it

I like the sound of this other tool which runs under Linux - it can't possibly be written in VB

But seriously, no offence intended to the VB programmers out there - it does have its place, and there are plenty of things that are easy to do in VB that are much harder to do in C!
One last, kind of off-topic, thing: would
"vertex" be a better term than
"node"? I have used the term "vertex" in my documentation for F-15 III, knowing that the EAW documentation used the term "node". Or is it like this: a "house" is not a "home" until someone lives there, and a "node" is not a "vertex" until it actually forms an extent of a line or polygon? I just think "node" is a bit too generic; one normally talks about a binary tree (such as the RS tree) consisting of a set of "nodes". Perhaps nobody will care to debate this with me

Regards,
David