I didn't think this out too much going into this. I'd just exported a single zbrush mesh into Max and started building a low poly around it. What I should be doing it re-export my zbrush mesh into different elements and make individual LP meshes for different elements? Because otherwise it's going to get confused when it comes to edges where different elements meet up?
If anyone can confirm these any of these thoughts, I think I'm right, just want to make sure before doing lots of work!
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I don't know what the problem here is ? just shift-select-move-explode your mesh piece by piece for baking and Voila! Its kinda what everyone would do in this case. Edge problem solved.
That is exactly how I would do it.
Also, model it as it needs to be in game. Does the door open? Does it need to hinge at a certain spot? Do you want gaps large enough in the door to see through?