Originally Posted by
dgorsman
We have similar problems, but the solution is simple. We use boxes to approximate the object envelope, then gradually union/subtract shapes to get a good compromise between design data and productivity. In a lot of cases a single box representing the exterior envelope is sufficient, with lines or circles used to indicate connection locations. Designers don't care if there's a slight dip in the middle, or if the sides aren't solid - it doesn't affect their design work.
We keep the detailed models, though, and load them up in Navisworks for model reviews while hiding the stand-in equipment.