This looks amazing! Any chance I can get a copy?
With the poly's with messed up normal, is it possible you're always reading the files in a particular order, when maybe reading by the vertex listing order is different?
How are you outputting to the .obj file? Most of them that I've seen list the vertices, then list the faces. I haven't dove into the format hard lately, although I did a few years ago. Do you need some help? I'd be willing to pitch in.
Regarding the normals, when you said messed up I thought you meant inversed - that's something a modeler could fix really easily of course, but I think you meant off. I *think* that's in an area under a building?
== John ==
P.S. I messed up my forum name - fairly new on here, so I just created a 2nd account, which I may need to do some Machinima with anyway. I'd signed up as jgwinner, then changed it to my normal online handle of "CodeMaster" (like Webmaster, only for code), then dove into the forum and I've seen what an unbelievable contribution CodeWalker has done ... and I don't want any confusion! So I joined as "MajorDisaster" my primary CoH Hero.