This has been BUGGING me as well. I will try the truespace solution, but there are a lot of related problems in MAX:
Boolean operations create malformed objects with stray polygons here and there, and that do not STL-check well. Anyone know a way around this, any alternative boolean plugins?
Further I have (right now, tonight) trouble with a vanishing arm... I have a character that initially has consisted of separate objects for each body element needs to be one contigous mesh. I just assumed it would be a simple 2 hour matter of boolean operations. Now its eleven in the night and I am still trying... Now my problem is that as I incrementally add one limb after another to the complete body now the arm suddenly disappear from the body as I add the right arm... why? The objects STL-checks just okay, and all is collapsed to editable meshes. Any pointers...
MAX just isn't very good for lowpoly stuff. Not in real life at least.