hey man
i also have the same prob but i assumed it was cos its sub d's bring a mix of poly an nurbs i thought there would be stuff like that - i thinks it is something to do with overlapping verts cos it only happens to me on complex models

but weneva i have done poly clean up it has totally screwed up my model for example it makes patches disappear - they r there in poly but wen u convert there r patches missing meaning revert to last save or start again so b careful wen using it

ne way gd luck wiv the rest of the tut it is aa good 1

damm portermalone how do c 5 sided polys cos i cant but there r a few parts where u need to use split poly tool to 'finish up' as there are some edges leading to nothing