: To return to the actual question I asked above, does this map corruption
: occur to alot of Forge users who hit the poly limit (or any other item or
: texture limit for that matter)?
Maps go corrupt for several reasons. (sometimes it just happens)
In your case, the problem is probably that you hit the limit of the number of vertices or sides or some such thing. I don't know what that limit is and Forge won't tell you when you've hit it. But when you do, 1st person view of the map in Forge will give you textures that wig out, walls that are invisible or pop up from nowhere, and various other issues, and if you try to merge the thing, you'll bomb (or nuke classic). The only solution for you is to see if there are no pairs of polys that can be replaced by one poly, or rooms you don't need, or stuff like that.
I had this problem on "Blasted Vent Cores". I ended up ripping out several sewage tunnels.
Good luck.
: Thanks,
: -Blayne