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I wonder how you manage to identify hard edges. On the models where I know where I set the hard edges, on import it looks correct. On models directly pulled from the game, I get hard edges, but they don't always make sense.
One little function could be added to it, if you get a hard edge, it would be nice to automatically get the EdgeSplit Modifier added with "Edge Angle" ticked off and "Shard Edges" ticked on.
When I try to export the xs_hat_vg.blend (attached) with vertex group sorting, I get an error message (vertex group export.jpg).
at some point this worked flawlessly, I just don't know which version I was using at that time. I might be able to reconstruct it if necessary.
I just compare the bytes that contain poly vertex normals in adjacent faces.
I think I know why there can be false negatives, but the alternative way that I tried didn't work out.
Before you say I sound like I'm full of shit, I did find and report a Blender API bug once =)
Also, please check if multi-object models come out okay. There have been complaints about joints that get mixed up and stop working interactively after a round trip through Blender. And I would hate to have brought back the old disappearance bug.
Unfortunately I didn't kept a history of all your versions and I can't find any old versions on your sourceforge page. But around end of 2013/early 2014 it should have worked. If you can give me all the versions I could check which version broke it.
I had to rename the vhot name
The next version I am able to export again is 0.3.20161124. With this the import/export of tu_s.bin is broken.