So an update on all this. Sorry to be inconsistant these days but real life pokes its ugly head in...
I've addressed the model issues (funnel/origin point/overly enthusiastic sweeps) and had a bash at changing the engine speed and adding some locators too. Reduced her by 10k tris just by optimising everything now I know how, so we're now at 24k!
@Pieter Boelen , the engine speed seems to be determined by the '/10' and not the Engine power line; I changed that to all sorts and it did nothing, but changing the multiple had drastic effects. I've settled it on '/6' as that's a good speed for my boat; about 10kn without sails, though I don't know how the frigates will deal with this...probably not well I'm guessing. Manoeuvrability is at a premium too, though I wouldn't say it's game-breakingly bad.
@Armada ; I did exactly as you said in Maya for the gun locator but no cheese I'm afraid. Perhaps it's me, but I placed a new locator at the tip of the gun called '_1', then grouped that under 'cannonf', then placed that group under the main locator (locator_1). Should this have worked or did I forget something? Obviously I have no deck view as I havn't done the path so my only way of testing the gun is by getting into a battle and pressing space bar when pointing at a ship...is it possible I didn't place the locator in the right direction? (d'oh!) Ie it's pointing upwards or something hence not responding? Also had a bash at the mast...but so far it's not even appearing in-game so I'll need to revisit that one.
Regarding your Guide, I notice at 7.2.1, you were going to enter further detail with regards to doing this all in Maya. Did you make any notes for it that I may be able to see?
If not I'll just have to not be so lazy and work it out in TOOL. It's only a flag and flagpole I have to do for goodness sake! Just makes me respect the complex rigging on some ships all the more...