Let me rearrange your post a little, to try to address one point at at time, since it's a little all over the place.
From: Bill Schmo
ok its all sculptys i export from maya thats doing it.. im toast.. heres a SS of the offenders next to some made with 3dsmax, see the cracks, lol
Image -->
I'll take this one first, since it's the easiest to address.
From the screenshots, it looks like you just need to rotate your sculpt map 90 degrees. Make sure you have Correct Orientation turned on when you export from Maya.
I'd also suggest you set your world up axis to Y if it's not that way already. SL uses Z-up, so it's tempting to set Maya that way too, to make it "match". However, the sculpt exporter script is configured to work with Y-up, since that's the Maya default.
From: Bill Schmo
My main issue is the seem down the side of the cylinder.. deleteing the ends made the prim more like a torus which is fine ( looks better then just bowled like it was in maya anyway)
You shouldn't be deleting anything, but we'll get to that in minute. Let's talk about the sculpty shape first. If you're going to be using cylinders as your source objects, you should also be using cylindrical sculpties in SL, not the default spherical ones. You can change the sculpt type with a script.
llSetPrimitiveParams([PRIM_TYPE, PRIM_TYPE_SCULPT, "uuid", PRIM_SCULPT_TYPE_CYLINDER]);
See the sculpty wiki for more info on that.
From: Bill Schmo
the end caps were the top and botom of the cylinder i believe it was the 1st -3rd vertices.. for some reason they werent part of the cylinder and llsculpt.mel script was giving me a error about textures (error: object list must contain a surface and texture) or somethgn to that effect (honestly im thinking that might have been caused by me doing something else wrong..
I saw that error once, myself, but I don't remember what the cause was. It wasn't anything difficult to solve, though. I do remember that.
In any case, you shouldn't be deleting vertices from NURBS surfaces, ever. NURBS don't behave like polgons. You can't simply delete a component, and then expect the surface as a whole to remain functional. NURBS are not made of individual faces, fixed in absolute space, like polygons are. Every NURBS surface is one unit, a singular entity, mathematically interpolated from control points. Remove any component from the equation, and you throw the math all out of whack, to yield wildly unpredictable results. Don't do that.
Once you've created a NURBS surface, do not touch the delete key unless it's to delete the entire surface. Consider all components sacrosanct. You can move control vertices around any way you like, but you cannot remove them.
From: Bill Schmo
I just went back into maya quick and just created a cylinder 32 spans 32 sections..
That's way too many. Remember, we're not dealing with straight-faced polygons here. NURBS surfaces are curvy. You want the resulting sculpty, which will be polygonal, of course, to be able to have some prayer of emulating the surface shape accurately. With that in mind, it's never a good idea to go above 16 sections and 15 spans in your NURBS surface.
From: Bill Schmo
selected the center verts and made it an hourglass shape, then tryed to export useing the llsculpt.mel script button that i added to my shelf and it gave me the "error: object list must contain a surface and texture" and it created another small version of my object inside the one i made ??? i dunno, lol
I'm not sure what's causing that error. Sorry. As I said, I've seen it happen once, but I don't remember what I did that triggered it. It was only the one time in all the countless sculpties I've made, so there was no good reason for my brain to make too careful of a note of it, I guess.
In any case, I can't imagine why a secondary object would be created, let alone a smaller version. Either there's something wrong with your copy of Maya, or your copy of the llSculpt script is somehow broken, or you're doing something strange in your work flow.
Testing the script is relatively easy. Just cut and paste a new copy from the wiki, and run it in Maya. If that solves the problem, then delete the shelf button you've got, and replace it with the new one.
Reinstalling Maya would be pretty easy too, although it would be a bit of a pain, obviously.
That just leaves option 3, user error. Try this:
1. Create a NURBS sphere.
2. In the channel box, click on the makeNurbSphere node. Set the sections to 16, and the spans to 15.
3. Export the sphere as a sculpty.
Did it work? I'll bet it did.
Assuming the above worked, now do the same thing, with a cylinder instead of a sphere.
If that worked too, now try it with sphere and/or cylinder that you've deformed in some what. Move some of the CV's around to shape the surface however you want. Just don't delete any components, and don't tear the surface. Whatever you do, keep it one contiguous whole, with 16 sections and 15 spans.
And don't forget to delete history, freeze, reset transformations, and delete history again, before you export. Keep your objects completely clean.
If none of this works, then I'm stumped for now. You'll need to describe exactly what you're doing in a lot more detail, every step included, before I can say for certain that it's not user error somewhere along the line.