For those who aren't aware, this is an update of Merl's 1.7 Custom Build of Zoner's tools. All of the features that Merl and Zoner added are still available in this distribution.
When you posted there wasn't, but I've gotten Merl's permission to post modified copies of version 1.7 with MAX_MAP_PLANES set to 65535. Replace your build tools with these versions and you'll be able to compile bsps with over 32767 planes. Then use my optimizer (included in the zip files) to make them safe for the game again. I'm putting them into two zip files since they're over the 122880 byte max file limit in a single download.
To use my optimizer, you can drag and drop your bsp file over it. The program overwrites the original file, so make a backup if you want to preserve the unoptimized copy. **Note -- since this program shrinks the map, it will checksum differently -- if a server is running the unoptimized copy and you have the optimized, it might not let you connect **.
Once the map is optimized, HLCSG -onlyents and HLRAD will break (make the optimization the final step when you're compiling), but it will run fine in the game. EDIT: If you get a 'file not found' error when running the tools, look at Ollj's post below, he has a solution to the problem. You can get the DLL he talks about here. If you still can't get the tools to run, two people have reported needing a second DLL you can grab from here, but others seem to be OK without it.EDIT 2/4/03: updated opt_plns to version 1.2, fixing the crash on bsp file not found and fixing a rare case of corrupted data for the first plane on the map.EDIT 2/5/03: updated opt_plns (in first download) again to version 1.3, fixing a crash bug above 32K planes and adding an option (-nopause) to skip the keypress prompt at the end of execution. The updated opt_plns is available as a separate program on the 4th page of this thread. Unless another bug is found, this should be the last update for a while.EDIT 2/8/03: well that was dumb of me . I posted the opt_plns zip instead of the modified tools 1 zip that includes the new opt_plns here -- thanks to [builder]hicks for helping me catch the problem.EDIT 2/11/03: updated opt_plns again to version 1.4, removing internal limits on texdata, visdata, and lightdata. Also added a -logfile <filename> switch and made input filename parsing more forgiving.EDIT 2/21/03: updated the tools to release 1.7p3, which speeds up HLCSG and fixes several clipping bugs as detailed here. There is a thread talking about the HLCSG changes here. You'll want to download the second attachment again if you have grabbed these files before.EDIT 3/13/03: updated the tools to release 1.7p4, which contains a threadlock bugfix, code that is more friendly to concave brushes, and a new -cliptype normalized option. More details are available here.EDIT 4/09/03: updated the tools to release 1.7p5, which added some new features and made some optimizations. More details are available here.EDIT 4/10/03: the 1.7p5 zipfiles contained the wrong version of the tools yesterday--my apologies to the 11 people who downloaded those files -- the links are now correct.EDIT 4/10/03: quick turnaround to version 1.7p6 to fix a show stopping bug related to the new BEVEL texture code in HLCSG.EDIT 4/13/03: released 1.7p7 added texlight support back into the tools and fixed problem of "too many direct lightstyle" message spam (you now will see the message once instead of every time the problem occurs). This is a stable release.EDIT 4/17/03: some people have had problems with the new lighting code, so I've added a switch, -oldmath, to RAD that allows using the older basic math functions. The new release has been tagged 1.7p8.EDIT 5/4/03: the -oldmath tag has been deprecated since I found the source of the problem. Also added support for the SDK 2.2 hull file format. Released as 1.7p9.EDIT 5/8/03: fixed a bug in opaque entity handling, released as 1.7p10.EDIT 8/15/03: maintenance release -- throw fatal error on buffer overflows that used to be silent, added location information to "too many lightsamples" error, using -verbose on HLRAD now displays ALL of those errors (there can be thousands in a single map). Added "-lightdata #" command so that people can add extra lightdata to their maps--doing this, like adding texdata, will require you to test your map on low-end machines to make sure that people can play your map. Released as 1.7p11EDIT 8/22/03: Rolling back publicly available release to p10 due to lighting bug report. Will release p11 again once the bug has been resolved.EDIT 10/3/03: Resolved the issue in p11, commented out spamming would-be developer message from HLRAD, reset default lightdata limit back to 6MB. Thanks to Kage and WolfWings for testing the release cantidates.EDIT 2/3/04: p13: Fixed bug in creation of objects without clip hulls, fixed bug in info_compile_parameters entity handler, changed usage of zhlt_noclip and zhlt_invisible to allow inclusion of those properties in .fgd files. Added Hullu's latest lighting enhancements.EDIT 6/1/04: p14: Fixed bug that caused errors building under default steam installs. Added switch to turn off light bounces for dynamic lights. Built optimizer into HLBSP. Raised internal plane limit to 256K. Added Reve's overhauled documentation.EDIT 6/3/04: p15: Fixed filehandler crash bug. Fixed face index crash bug. Added switch to turn off plane optimization. Fixed SolidBSP display times. Fixed bug with opaque entity lighting. Changed chart output to display planes percentage based on Half-Life plane limit.EDIT 8/15/04: source release: I've released my latest source a few days ago since I've been hired by a game company and won't be working on ZHLT any more. Notes about the release are in the original posting on page 33 of this topic; I forgot to post a first-page update when I uploaded the source, but it's here now.
Enjoy! Latest download: ZHLT 1.7p15