Alright, so after a painful ordeal of making modifications to Don's QS, , how do i know where to break up the model? does it have to be along the exact same lines as Don, or will rough approximations work.

My experience has been that they don't have to be exact but the closer they are, the less twiddling you have to do to the blend zones.

You'll be surprised what you can get away with. :) I try to go to the nearest existing polygon to the base figure's groups, but there's usually plenty of leeway.