What the fuck?! No. Just no. You don't solve problems with modular assets by making them NOT MODULAR ASSETS. The "fix" you're suggesting is lazy, inefficient and bad practice. Doing something like that should be a last resort.
You're usually gonna be better off fixing the technical issues and/or creating geometry seams on the edges of the modular pieces. It does depend on what the modular pieces actually are though. If you're making individual floor tiles then yeah you're doing it wrong - if you're talking about 2metre by 3 metre wall sections,…
To solve light bleeding use 4 pixels between each shell not 2. To solve seams between modular meshes: Combine meshes in Maya and import into UDK as one larger mesh. Also merge the verts along the seam, and merge the 2nd channel lightmap UVs so that they are one continuous shell, then use a larger lightmap size if needed.
That's why I said: What I am suggesting is pretty much the same solution mentioned in the Modular Floor Tiles - Outlined in Shadow thread. It's not like I'm suggesting merging an entire level into one giant chunk. Just merge things into chunks that make sense to keep visual seams to a minimum while also using a mixture of…