yes, physically separated into several meshes. exported and imported into UDK separately.
yes. the parts of the Pawn are defined in Unrealscript
No, it has nothing to do with the bone naming conventions. the body parts use the same rig regardless of the bone's names
with "imported" I assume you mean "merged into the same Pawn" right?.
if you use 3ds max, your body parts will be separate meshes but they will all use the same skeleton. In-game the theory is the same, for each mesh you want you add code for the pawn to load it and use the same skeleton+animations.
I don't understand what you mean with "the different options" though
good, this is a good way to go.
I myself do it in a different way: picture in your head how a weapon is loaded into a Pawn (it's attached to the pawn via a socket). Now imagine that the weapon is actually an armor piece. Now imagine that instead of attaching it to a socket, you just attach it to the base of the Pawn, and then tell the armor part to use the same animations as the Pawn.
It's a whole different way with its advantages and disadvantages, but it suits me better. If you have no experience though, the modular Pawn is probably a good idea for you, since it's well documented

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