i saw the question at an8 but didnt get what you asking do you have url to the ginger beard tutorial i couldnt find it heres some tips sometimes when you merge points then convert to sub object they leave holes what you do is select all the faces then edit deattache faces then when you convert to subobject again the hole should be gon if not delete that vertex/point then make a new one and select all edges around the hole and edit>fill holes another way to find hiden edges witch make holes on subs is to select a face the goto edit>select>select by connected then edit>select>select face edges then change the select mode to points/vertex or edges and do edit>invert selection now delete after all that go back to object mode and change the working on the subobject to 1 ok it then put it back to 2 hope this info is of use to you