^^ In Blender 2.70 that remove orphan vertices export option always seems to cause the errors box. If I select the apply modifiers it flat out crashes Blender. You may have to bite the bullet, and go hunt the orphaned vertices down. If you select all faces and hide them, then change to select vertices and select all the orphans will get selected. On a more simple model with no split edges, I'd just say hit remove doubles, and carefully move up the separation distance for merging until the bar up top indicated some vertices were removed, but parts of your complex model could get messed up without you even noticing. Not sure if it actually matters, but you have 'double sided' checked on all those mesh groups. Great model, btw.
Not sure if this addon semi-broke with 2.70, but it's almost impossible to create any animations. It's like it's reordering the parts on export, yet it hasn't according to the D3D9 debug menu within Orbiter. I got it right once yesterday Then decided to remap my UVs on some replicated parts (landing legs) which required deleting the duplicates, and cloning/rotating the one I remapped, so now the animation looks all wrong again. It's even moving a mesh group that isn't even designated to move at all in my Spacecraft3 script. I applied rotation and scale to the groups, so it can't be that.
---------- Post added at 06:53 PM ---------- Previous post was at 06:34 PM ----------
Just an off the wall guess I found the first group in the Spacecraft3 ini should be 0, not 1, so the last mesh group in the list that wasn't supposed to move was being forced to be the first mesh group in my Spacecraft3 script. Weird, but now it works correctly again. I think the way that Vlad's Blender addon imports and labels mesh groups starting with 1 instead of 0 threw me off, at least with Orbiter's included meshes. lol
Maybe Vladimir might help us out if he has spare time, and review the addon's export options in 2.70. They tend to break addon functionality with every few versions of Blender, but at least it's not completely broken. Those are export options for convenience, so I won't nag anymore than that. ;-) Thanks everyone.