Holes in Long Objects + Smoothing Issues

cadgonegames

So alot of the models I make for work tend to have an awful lot of holes cut into the sides of objects etc. I always try to 'box in' the holes and just tidy up the geo around it to keep it as clean, but not as optimized as it could be without having long edges running along a cylinder for example.

Mostly this works ok, minus the annoyance of a higher poly count than I could achieve tying up edge, but I get some ropey looking areas around the holes, which I guess is in relation to the way I've did the geo around the hole.

2 Question if you could be so kind!

A: Is the box in method the best way to tackle this?

B: What's causing this error? (Ref Attached)

Thanks

cadgonegames

The high poly model is fine, I've remade the low but it just isn't working at all for me.

I've attached a few more shots, i'm a bit clueless at the moment why this is breaking.