Hi PaQ - that's great that you have a solution that is not labor intensive!
The other operation that may help in Modo is if you hit flip twice.
I kind of remember now hearing that doing that will also rotate the points of a face to put the first point of it at a convex vertex (can't seem to find the reference now in the Modo forum), so that may be another option if the align tool does give you any normal map problems.
Maybe they have tuned up the align tool since the time you had the problem with the headphones, so that it does not disturb the normal map.
By the way, cool ship! I hope you may be able to post some snaps of some of the other ones that you are building.
- Michael
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