I read that by exporting your VC model in parts, and then naming the _interior.x files as interior_100.x, _200.x e.t.c. you can trick makemdl into merging them into a single object. I did try to do it and it doesn't work at all.
Makemdl doesn’t “merge” them, it outputs an .asm file for each (with "keep files" checked), and with some simple edits to the main .asm file to remove the LOD tags (IFSIZEV, IFIN1, BGL_JUMP_32), you can then compile with BGLC_9, rename the .bgl file extension it outputs to .mdl, and be free of Makemdl’s limitations.
Looking at your error log, it looks like the trouble is with "B717_200.x" and possibly “B717_200_shadow.x” being too big. I'm no expert on Makemdl error messages, but those probably relate to the "B717_200_full" and "B717_200_2" the log references. If I recall correctly, the message: “error A2071: initializer magnitude too large for specified size” means that part of the model is over the limit, and you’ll need to shuffle some parts around or split that LOD model and create another LOD model that’s under the 65K ceiling (sometimes easier said than done – I know). I’ve only had one of those errors, and it’s been 2 years ago or more, but I think that’s what it’s squawking about.
Has your exterior model ever compiled successfully through Makemdl before you tried it as an LOD model?
For the other errors - “error A2006” is the compiler choking on discreet LOD’s for the VC, since they aren’t supported for the interior model. You can ignore those - when you compile with BGLC_9 it won’t care about that.
I also tried doing it using only some parts of the interior with a vertex count still over the FS9 limit -just in case some parts were corrupt.
I don’t understand what you’re saying here - especially the bit about interior parts with a vertex count over the FS9 limit. Did you mean "parts" or "model(s)"? And if you're talking about the LOD model you made, if you know it’s over the limit, then why try to compile? Makemdl will still choke on a big model, it doesn't matter what it's named. The goal here is to feed it small chunks that won't upset it, then assemble them from .asm files and compile a final model with BGLC_9.
Before you go further, I think the best way to get started with this is to create some simple test .x files - a box or cylinder will do – then name them as LOD, and run them through Makemdl. Edit the resulting main .asm file to remove the LOD commands, then compile with BGLC_9. Once you’re familiar with the process,
then you can try it on a complex project.