I've been quietly shifting from using props at all. The technique of a conforming-figure prop with phantom limbs for the "conforming parts" seems to work very nicely. I've a couple hats done that way now. Advantage is, of course, that they take MAT poses and can have posable bits. Has the boat drifted completely from the pier yet? By the way, you can split into multiple obj files, but it is my impression Poser does something silly with the rsr when you have AltGeom dials in the cr2. Oh, I've never worried much about thinning out the size of the obj file (as opposed to the size of the obj); I've done some looking at my own Runtime and discovered that once Poser is done importing the file has bloated up to the same as it was before I stripped the normals.