I have done quite a few damage textures now. Some ships dont seem to display damage as well as others.
According to the manual in SFC3 model tools which I recommend people read. It explains damage maps good and even how to go about texturing a little. Basically the game assigns parts of the damage map (it uses different parts but never the entire map at once) to certain of the different 6 hex sides. Hence the a1-3 b1-3 c1-3 d1-3 e1-3 f1-3. Sometimes if you add lots of detail. The game might cut off the damge in places that make the detail look odd. Like you might make a hole in the hull but only half the hole gets assigned.
Where the damage gets applied is affected by where you put the damage points. So its best to place them more on top then bottom. I founf that the fewer maps a ship uses the more even the damage looks. Damage gets cut off abrubtly on ships that use 15 texture maps or more.
What you do to make a map is just take the original and 1st darken the entire map. Things that work are charcoal, crhome or adding smoke and noise and lowering gamma correction. Then select areas for hull breeches. I use the freehand option and make jagged areas thruogh out the map. Then I might do a fine weave, smoke, fire, glass, chrome fire, swirl and a light orange glow around the edges. No 2 of mine ever come out the exact same.
I wanted to post the part in the manual but couldn't cut it to paste from the pdf file.
Here is an example of 1 that has some hull breeches detaaled in. This 1 is getting cut off a bit. Its not too bad and is fairly common. Where its getting cut off is where 2 parts are mapped ti different maps. The strut is on 1 map and the saucer/hull is on a different map. If this entire bottom was mapped to a single map, the damage would flow and blend better. Just another consideration. Overall though I prefer how SFC3 handles damage better than OP. Also just want to say that I love SFC3. I have seen people say that the ships look no better in SFC3 than in OP. Thats not true at all (though might be with an outdated video card)