wrote it up
Technical requirements and guidelines for models:Models should be within reasonable poly count limits. We won't define a number because graphics cards can handle so much these days, but use your best judgement. Make sure you give round areas enough tris to appear genuinely round.
The end result should have a normal map and any associated specular/env_cubemap maps. For more information on what maps the Source engine is capable of using, refer to Materials for Models on the Source wiki.
We will generally be using heightmap normals on our meshes instead of baked normals. Our process for generating normal maps will be as such:
1. Create the model's base mesh
2. UV the model as usual and create your textures
3. Use a program such as Crazybump/nDo or the Nvidia/xNormal plugins to generate a normal map from a black and white heightmap texture
For mechanical items, the process we will be using is described below.
For complex hard surface prop/weapon/vehicle/etc models:Don't bother creating a high poly for normal map baking unless you really need to. We are going to try a different approach which should give a similar effect while making it easier for newer developers to contribute...
Let me preface this a little. Tangent-space normal maps are used to modify the lighting direction of a model. By creating a high-poly model and baking a normal map from that, you are essentially "correcting" the vertex normals of the model (lighting direction) by using a texture. In short, the reason for doing this is:
1. Corrects smoothing to look like the high poly model.
2. You can get nice round edge-bevels on models without needing geometry for it
3. You can capture dense, complex high poly details down to a simple low poly mesh.
However, the process of creating a high poly model can be very time consuming, and even most professional 3d artists in the game industry do not fully understand the process of creating a proper, clean normal map. Since this is a mod, we need to simplify so everyone can help out.
So, instead of doing all that complicated stuff, we are going to take a simpler, alternate route which should give us the benefits of baked normals while still being simple to understand for someone who isn't a professional.
Instead, we are simply going to add edge bevels on our low poly models in important locations, then do fine details using a heightmap in photoshop. Below is a quick example that will be replaced once i make a full weapon:

The benefits of this are:
1. Better smoothing where it needs it
2. Attractive edges bevels catching light where it needs it
3. Heightmap normals allow us to give it some extra details
4. Easy to understand
5. Faster
The downsides are:
1. Creates a lot of extra, thin geo.
2. More difficult to UV
3. Only gives better smoothing and edge bevels in the most important areas, not ALL areas.
4. Requires more photoshop work than usual.
Things to focus on:Make sure your smoothing is very good, though slight warping is acceptable because it will get covered up by the spec map. Make sure your edge bevels are wide enough catch light. Make sure not to add edge bevels where they won't be seen. No ngons or dumb bullshit please, I value a clean mesh over low tricounts any day.
Afterwards we should end up with a nice smooth model which attractive edge bevels catching light. Then to texture it, you can do it like any other "current gen" dynamically lit weapon. If you don't know how, give it a shot! It's a lot of fun representing materials as they actually are.
Here are two good tutorials to help get you started:
http://www.oesterkilde.dk/racer445.phphttp://www.marmoset.co/toolbag/learn/materials