They asked for no lighting at all, so I'm trying to build it the cut way for the most obvious parts (in case they want it lit as a next step or test it themselves in their engine). Thanks.
You can skip the greyscale step if you can set up gradients as textures that are mapped by vertex normals (it's possible in Blender, don't know about other apps).
The gun models are looking slick-- for the Halo girl, I think it would be best to work all the shading up at the same time, and then differentiate each material in it's own step.
Yeah, that's the first step. Or fresh install. If you don't mind using OpenEXR format, you could try Splutterfish's plugin: http://www.splutterfish.com/sf/WebContent/DownloadTools