Hey Jeff,
I saw your original "face move" post. I got the same error
when I followed the steps in your post. I was sort of waiting
to see what others might have to say about it.
My first instincts were that there is a maximum block/brush size.
I have used valve-hammer for texturing and compiling .map
files for torque and there is a block/brush size limitation.
I looked to see if there was a maximum block size in WED, but couldn't find
one, but I'm pretty sure that the face movement is not creating
concave geometry.
Just out of curiosity, if you want to do a little experiment:
-create a large block and place it at the world origin
-move the faces 128 units at a time and tracking the number of face moves
-when you get the error, figure out based on the number of face moves the
approximate size of the cube when the error occurs.
-if you post that result, I'll make and export a .map file from 3ds max
and then try opening it in WED and see if it gives me any invalid
block errors.
The easiest solution that I can come up with to deal with this
issue is to break the subway tunnel up into chunks. If you create
one chunk and group it together, you can easily duplicate it and move
it where you need it. As long as the blocks are aligned, and the textures
you are using tile well, your blocks will appear "seamless," which is what
you're probably wanting since you are trying to create the tunnel as one
big block.
Also, by using this method you could use the tunnel piece as a prefab,
and use it in other levels in the future.