I believe the max poly count is around 50k if it is optimized on conversion...
Well, the convertxsi.exe have a limit around 50k tri but it is not the limit of the iron engine...
There is some work around who allow to have more poly...
By example, let say that you have a model with 75000 tri... when you model it, you can put all the detail in a secondary mesh... main hull with big piece will be model_part1.mesh and detail will be model_part2.mesh... on the model_part1.mesh, you create a hardpoint for particle effect located at 0,0,0 , let call it "flair-call_part2.particle"... these particle file can be created with notepad... it simply use the ship shader ( GS_ship ) who render the model_part2.mesh...
Why work with a main and detail section, why not simpply cut the model in 2? Well, a problem with using particle is that it is not show until the model is finished to be build... will look ugly to have a half ship being build in your shipyard... second reason is that part render via particle don't count for collision detection... you will have ship or fighter/bomber who can fligh through the second half ( this can be corrected by editing manually the bounding value, not needed if only detail are on the secondary mesh ) ...
Some will say that high poly count will slow down the game... have make some test a few month ago... over 100 starbase in a single gravity wheel, starbase with 65k poly... total, 6.5 million on screen, using a low end graphic card ( nv 9600 gs 256mb ) and no slowdown... have add more starbase and problem appear around the 10 million poly... only because of the colission thing... too much big starbase for a too much little gravity wheel...
The only potential problem can appear if you make a mod with a lot of races... these method increase a lot the amount of .mesh files... and the sins hardcoded limit is 800 .mesh for all the game... same thing if you make some rotating pieces... each piece use a .mesh ... more bad, i am working on a animated model now, only 1.5k tri... but a little over 10 .mesh !!!
I don't understand how 32869 triangles can have 64.5 vertices
Have already see something like this with a badly exported model from sketchup... almost the full model is exploded in his individual triangle and don't make anymore a volume... more bad, after using the convertxsi, the amount of triangle is double... since triangle are individual piece, you have 2 side on the triangle...
... and im getting mini dumps so i guess...
Don't guess... use the dev .exe and look in the logs... a model can crash for a plenty of reason... bad hardpoint, bad geometry, there is a thing about hangar and squad, and more...
PS : a lot of model error, like double edges, duplicate vertice, non manifold surface, holes, bad normal, flipped faces, exploded model, etc... can be corrected in a few click with meshlab... it is a free software !!!