Not using subD. It's just a poly mesh with 2 subdivison levels mesh smooth applied.1. the smoothed model...are you using subD's? or just smoothed polys...
Depends a bit on what I'm doing. For connected mirrored geometry I've found it nice to start with an outline of the mesh in the sideview using the create polygon tool. Then using the split polygon tool just add some major geometry lines going across that outline, and extruding them out. (see picture)2. Are you starting with a box, and then refining it down? or are you starting with something else?
Nope, just polys with an extra edge or two to mark the contour.3. on the edges where the armor meet the cloth...when you smooth the model how do you manage to retain the harder edge there? is it creasing in subD?