Interestingly, I have tried all these things as suggested, I created the boxes one smaller than the other for the hole as per usual, Made them both editable polies, then boolean operations, the converted that to editable poly, then I dide a few little face chamfer's and stuff to make it a bit smoother, smoothing grouped ect. Uv mapped with no troubles at all and set poly id's for all the parts, then attached all the corresponding boxes and exported
Just a question, is there some where to view unseeable faces? maybe the face that is causing this problem is somehow invisible in the viewer? its a rather confusing situation as I have used boolean many times before and its imported just fine, yet I have tried remaking these boxes twice now and nothing has changed...