Hi WEN
40K sounds about right for the completed model, and I am intending to do at least 3 LODs. The guidance I'm following re re poly counts is here-
http://online.ts2009.com/mediaWiki/index.php5/Modeling_Trains_for_Trainz (Not sure if you need to log in to the wiki in order to view?). I figure that multiple units are some way between coaches and locomotives so I don't feel too bad about being slightly over the guidelines for coaches at this stage. There are also quite a few hidden faces to be deleted, but I don't want to do this until I've finished the AO baking process since many are needed for this.
In my opinion m.tbumpenv is the material of choice for all rolling stock, because it is possible to have both matt and shiny surfaces in one material, and because it interacts well with the sky and world lighting conditions. This means that I can have have matt weathering on gloss paint, for example. I'm also experimenting with the normal map to see if I can get a slightly rippled effect on the metal panelling. I might be able to get away with 1024 x 1024 for the interior mesh- I'll see how it looks when reduced after adding the real textures. By the way, the interior is only the passenger compartment, and not the driver's cabin, because I want to use an alternative mesh/texture to simulate night lighting. I managed to get this working in my original Cravens model and think it would be nice to do the same on the upgraded version if it doesn't cause too much of a performance hit.
I'll still need separate textures for the alphanumbers, destination signs, set nos. and servicing days etc, since I want these to be changeable by texture replacement.
I made the roof using a subdivision surface modifier, with 3 or 4 subdivision levels applied, to a cube. The faces of the cube had been divided into four to give enough control points. I then manipulated the control points to get the subdivision surface to follow background plans, and just played around with it until it was right for half the roof. I then applied the modifier and deleted the bits that weren't needed, and then applied a mirror modifer to complete the dome. (I'm using Blender but I guess you can do something similar in 3DSMax?) This method is easier to do than to describe!
Your 502 is looking fantastic, by the way- great to see the blue/yellow version in the UK screenshots thread today.
Cheers
R3