Hi,

Sorry I seem to have caused confusion, and then dissappeared off to sleep.

I was suggesting using the UV's to identify which vertices should be in the same place on the meshes. Looking back at my post it was confusing and I apologise for that.

Regarding the squared thresold calculation:-
Could you multiply your figures up by , say 1000. Do the calculation and then divide the results by 1000.  eg

(0.006*1000)^2 = 36    /1000 = 0.036

Cheers

Ian