Hi guys, sorry for the late reply… been a little busy here.
anyway, lets answer some questions!!
nightwoodwolf - the new approach we are playing with now involves a little programer help. its a plugin. but hopefully it will be worth it! you’ll have to wait though for full details
so yes, the textures are all hand painted inside of zbrush. there is no photo layering on top. just straight up poly painting or texture map painting. Drake and Elena were made in zbrush 2 so there was no poly painting at the time. The maps were made with just projection master. Poly painting now is much better though!!
Jim- yes, i’ve had those same issues. I’ll tend to do a similar approach by making a separate map for cavety that is black and white, then bringing it into photoshop, blurring it a bit, and overlaying it on top of the color map if needed. Recently i’ve just been painting with cavety turned on in poly paint. It does get a bit jaggy but i just smooth and paint over it after. I’ve always found that too much cavety for humans anyway tends to make them feel a little rock like… so i use it very minimally… I used it for the mummy however and just painted over the jaggy edges after and it worked fine… but yes… its a little frustrating not being able to adjust how it blends…
I dont really think increasing the poly count makes a difference. I’m pretty sure its just the way they calculate the cavity. The mummy was around 8 mil and i still had those issues. but who knows… i’m sure you can find some ways around it… i guess it really depends on how accurate you need the cavity.
piz - we’ll see 
Zanrok - what exactly would you like tutorials on? i’ve always been thinking of doing something but there are so many tutorials out there already that its hard to really show something unique. let me know what you’d like to see and i can see if its something easy to put together…
alannoon- the secondary characters, pirates, etc, are a little lower in quality. Quality meaning less polygons, smaller texture maps, and fewer texture maps, as well as reduced material properties. The reason for this is obvious. They were not the center of attention and did not need to be as high. They still do have a nice ammount of detail in them. We managed to pull off some impressive results with the small budget we had. Tyler Breon and Ricardo Ariza were the artists responsible for all the secondary characters. I can’t really show thier work for them though, they are on these forums and actually replied in this thread. Ricardo is on vacation now, and Tyler switched over to Sony Santa Monica. You might want to hit them up and hopefully they can post thier work!
Environment guys I guess dont like to show thier work either. I’ll try to hit them up too… just up to them ya know.
AikoWorld - glad i can help!! 
thegraybox - yep, they are screen captures from maya. The only thing i did was put some depth of field blurr in and clean up some of the jaggies since maya doesn’t anti alias. so yea, thats what it looks like in the viewport… remember, these are our custom materials where we overwrite maya’s opengl settings for our own. That allows us to have our own custom cgfx shaders that pretty much are the ones used in game. We dont have a direct connection to our game, yet, but we can tweak all our parameters in maya, then just export it to the game and view them in there. There are some limitations but overall its the same shader so what you see in maya is pretty much what you are going to get in the game.
maya is very tightly integrated with our engine. We have a ton of custom tools and plugins that allow us to pretty much do anything in maya and have it come through in game. Its almost like our own custom version.
hope this helps… i know its a little ambiguous i just can’t really get into specifics since its all proprietary software.
slashpot - Thanks for that! girls are hard work! regarding her hair, i gave a somewhat in depth explanation on how i created it on one of the past pages. If you have any other questions feel free to ask!
thanks again everyone for your comments!
-Rich