My maps are 2048s. I try to limit myself to three sets of 2 2048s....one set of Diffuse, one set of Specular and one set of Glows. As to the materials, not sure what you mean by that, but if by that you mean different texture effects, its all freehand. I dont usually use materials, I like to draw the textures out...longer to do, but I can get them to look exactly the way I want.
Hey..
So based off this, in Max, you'd have one material. Diffuse (main texture), Specular, and Glows (self-illumination).
All those'd be assigned under one material most likely. Think of materials as being slots for textures, and each slot can hold diffuse, specular, bump, ambient, and self-illumination. (may have missed one). IM's Firefly (that I'm currently building illumination maps for and beefing up a bit) has one material (as yours) and that'll have:
firefly.bmp (diffuse=main texture)
fireflyi.bmp (glows)
fireflyD.bmp (damage texture, read in by SFC3 and not assigned to the mesh)
fireflyiD.bmp (glowed damage texture, read in by SFC3 and not assigned to the mesh)
fireflyBS.bmp (beauty shot, read in by SFC3 and not assigned to the mesh)
fireflyTI.bmp (tactical image, read in by SFC3 and not assigned to the mesh)
fireflyVL.bmp (computer library image, read in by SFC3 and not assigned to the mesh)
So that's seven textures for the ship, seven read in by SFC 3 (five not attached to a material on the mesh), two read in by SFC 2, one read in by SFC 1.
Which actually does make making a SFC 2 mesh fairly easy to convert to SFC 3 in that fashion.. you don't have to play with materials in Max or Milkshape. just copy the diffuse and glow textures to *D.bmp and rough them up. And then create the beauty, tactical, and visual library shots, glow the ship (if desired and warranted) and you're done more or less.