I have a OBJ that I am importing into Blender 2.5x (using options Object, PolyGroups and -X90).  I have created a Box UV for it in UV Mapper, and it shows if I go to edit mode, select all, and go to the UV Image/Editor view.

Whats odd, is that I can find no seams on the OBJ in Edit Mode. 

So, instead, I went ahead made sure to select all, and "Clear Seams" and retry the UV Unwrap. 

After the operation was complete (in Edit Mode) I switched back to the UV view, and there is a different "cut-up" of the suit!?  I would expect it to be all l one piece.

Any thoughts about the OBJ import, and how it may be figuring out how to "cut up" my suit OBJ?My guess is that it is breaking it up per the grouping (i.e. Import setting for Polygroups) that I used, since there seems to be a Neck unwrap that looks similar to that group?  I dont find anything that says it unwraps by group by default.

In fact, I already had did this and added seams, and it seemed to combine the cuts?  Maybe there is a "how it unwraps" setting I am missing?  I will keep looking, but wanted to ask.

My goal is to start anew, place seams and unwrap.

Import the .obj

Edit mode>select all>clear seams

With all faces selected U>reset

Your UV layout will turn into a blue square that is comprised of every face stacked together.

Now place your seams and unwrap again.

You will have islands made up from the cuts you indicated.

Adjust as necessary.

Thanks for the reply, but I did everything but replace the seams, I just unwrapped again to make sure all was OK, and it still unwrapped to multiple pieces...very aggravating

So here is some pics  (I even tried a latest blender build....at wits end)

...and here are the UV's I am getting:

I have cleared seams, and Reset the UV

After that: U->Unwrap

I suspect it is separating the UVs by polygroup since you had that checked on import.

Yea, thats what I was thinking, and it is how it seems to be seperating it.  ...but just tonight, I re-imported the OBJ with nothing checked, and it still seperated it in the same manner.

But for kicks, lets say it is...do you know how to stop it from doing that?  Is there like a "settings" for how it unwraps, or the rules it uses?

DARN!  I figured it out...after the above thought, I wondered if maybe it is not cutting it up, but that it is already cut up?  This is an OBJ that I mod'd in Blender, and then to Poser 7 for grouping, rigging and create of a CR2, etc.  That left me with an OBJ which had seperate meshes (or in blender terms, a lot of Duplicates!)  I removed Duplicates, re-ran it and voila!  Only 1 vertice, out of sorts.

So....the next question is....is a UV map of this now even usable,since the vertex count is different?  I am thinking so, since I've seen some workflows where they use low poly to create UV's and then subdivide afterward for a smoother model.

Can anyone let me know on that final point, I dont want to take the thread too far off topic.

The UVs are based on the polys so I don't know if the map would be valid.  I can't remember if Blender has a way to save the UV data as a separate, I use UVMapper Classic for that.  If it does I would do that then try applying the profile to the original model.

The most likely causes are that you haven't specified any seams and/or you've specified the wrong axis to unwrap on.

I can't be more specific because the larger images can't be seen without a Flickr account.

You could always ask in the UVMapper forum as UVDan may be able to assist.