Yeah, with the limited texture space I was allotted I was annoyed I ran out of room for a secondary texture that I could have vertex blended in UDK to break up the repetition. All three variants of the gears are sharing the space of a 512 texture, which was obviously not ideal for such big pieces. Making them smaller and…
Do you have an example of that? Because I'm still not quite understanding what you're getting at since you did first state to make cuts in the cog and I took that to mean a gash through the piece (not a texture or surface cut) and a break would be one of the gears "teeth" removed or disfigured via geo. EDIT: Got Vertex…