No, not babbling :).  But I do think we covered this particular subject before...

I'd have to see the specific example to figure out exactly what the problem is, but remember your earlier test of that super low poly Poser mesh head?  A few vertices on the back of the neck area 'missed', because the vertex normals point downwards slightly and so they passed under the source head polygons.  Scaling one mesh up/down a bit and testing in world-space fixes that problem.

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