Thanks everyone! As for how I split the model up for print. Well, I left that to my vendor that printed it, He used Freeform which has a great solid modeler tools set for cutting and booloeans. I know that now with dynamesh it can be done in ZBrush, in fact I think there is a really great thread here on the forum that goes in to that whole process with DynaMesh. Maybe some one can repost it.
But we worked together to design a system of keys to make sure the parts go back together like a model kit. Also we chose obvious places to break the model to help hide the seams. I did have to cut the arms mid way. I used to try and hide those cuts in folds, but I found over time that its best to make some cuts mid form For example I cut the arms mid bicep. That way the seam is easy to get to for filling with putty and sanding.