I have a suggestion, it may not work, and you may have already done it, but basically, when you boolean two objects, it still knows them as two seperate objects. Have you tried collapsing the modifier stack down so that all remnants of the old objects are gone? Sort of like flattening all layers in photoshop, it's impossible to go back and edit an individual layer. This may help in the exporting and importing process. I'd be highly interested if this works. Dragontales