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Thanks for the suggestions Bryan. Do you think that producing the core without the door details, etc might solve some of the stepping problems as well since it could be sanded?That said, I don't have the skill set currently to produce a core in CAD. Then there is the issue of not having any drawings to utilize. One of the Mod-U-Track guys (who doesn't post here) has measured an H10 or H12 recently so that would be a big help.
... I have considered splicing the shells, sanding off the doors and using the cutter to create new door skins. Maybe even use BLMA etched doors if anything is close enough (haven't looked to find out yet). The hardest part is to replicate the louvers in the doors and those aren't done all that well in the model anyhow.
I apparently haven't been here long enough to post pics yet...