If I understand your question correctly, you should be able to scale elements of the same object by using the transform component tool. I'm not sure about the second part, I usually just group them, scale, and ungroup.
I had the same thing happen to me, I think my problem was that the object wasn't on 0,0,0 when I exported it. If you're using Maya, make sure to place the object in the center of the world and to freeze all transformations.
you need to use the mask and transform tools to move them apart from each other. Dynamesh aproximates at lower sub d's so anything to close will become fused. I'd recheck the anatomy on those arms. :D
you probably froze transforms or deleted history at some point and now they are in different coordinate systems. I would go back in saves (you saved incrementally with an unlimited save amount, right?) until you find the error
reset X- form go into animation hiarchey transform/scale reset pivot 0,0,0 make sure ALL quads no 5 sided NO Tris Also apply a relax modifier on top of it so all polys are equally spreaded .
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I'm kind of confused what you're looking for. You want to make it a shell without adding the additional faces an extrude would create? Anyway, if you're looking for the move component tool in 8+ it's in Edit Mesh->Transform Components
Absolutely, it looks almost like a cell shader (which is not intended :D ) I think it relates to the lighting, somehow the metal pieces are not picking up the reflection properly. Already started transfering it to Unreal which I will use for the final renders and hope it is something which will just go away with proper…
Certainly transformed into something so much better. The angle is also good. You said rough lighting so probably premature but the shadows in the far back, right side are a bit too much. I'm sure you'll fix. Carry on.