[Brett Thayer] “Should I go higher? Say 96? “
The higher you go the smoother but more work to connect the bits later. I would try going lower and let subD surfaces (HyperNurbs) smooth it later – assuming that gives enough control. HyperNurbs are very flexible though and there is more than one way to get smooth bits and sharp bits in the same object. In the example I sent the edges are relatively sharp as I bevelled them to increase the geometry and sharpen the nurb – you have to have a basic understanding of how hypernurbs works to know what to expect.
[Brett Thayer] “Now I copy the section parts I need to remove and create new booleans to remove the unneeded sections? “
yeah, if you want things to fit together and you need holes to connect to there is nothing better to cut the hole than with the object to connect with. The geometry matches perfectly and connecting later will be easier.
Booles make extra triangles (they have to) wherever possible clean that up before connection, some tri polys can be turned back into quads, some places points can be Welded.
Part of the problem with the first example was that the rims of the pipes touch if that has to be ah well, but if not it’s a lot cleaner to just join pipes.
I’ll take a look at the next one in a bit