the new pose tool should be able to do a great job of that i think, duplicate the object first.. hide it and pose the second one with a gradient that is heavy to one colour and it should just bevel it straight and clean, then use the duplicates to boolean in and fix any pieces.. other than a few more subtractive boolean methods that's all i can think of.. .. exporting your object for use in 3DSmax or maya, and creating another OBJ, using their precision.. then just export that into 3DCoat and subtractive boolean