Arno, for regular, rectangular objects, the crash-box as used by FSX is already very accurate, since the bounding box of the object is used to "trim" the 4m. square "crash cubes" (not 3m. as I said in my earlier post). However, if you visualize a T-shaped building, the bounding box encompasses the "hollow" areas on each side of the leg. In those areas, the crash box is defined solely by the outer edges of the "crash-cubes". Hence, errors of up to 4m. can be expected. So, it would seem that a better definition of the crash-box in those areas will requre a reduction in the size of the "crash-cubes" which, unfortunately, will consume FPSs. Certainly, the solution to my problem would require a very significant reduction in size - probably to the point of being impractical.
However, it's not clear that the current arrangement of the "crash-cubes" generated by the Gmax game pack faithfully reflects the actual shape of the object. For example, with my CYYJ terminal (which is very complex), crashes were (until I added the <NoCrash/> option) experienced much further away from the building.
There are 8 sequential-bytes in the crash-box section of the .mdl file which were set to x00080001 in every file I examined. I was unable to determine their purpose which, hopefully, includes cube resolution. (But I was focussed on very small objects.) Perhaps you'll have better luck.
The FS9 tool you are referring to was written by a user named "anatolij" who hasn't posted in a while. All the links I've found to that tool are invalid. So, I've e-mailed "anatolij". Hopefully, he'll "surface" this week. (At least the e-mail didn't "bounce".)
This thread contains most of the useful information on crashboxes available on FSDeveloper.
Hopefully we'll soon see a new version of MDL Tweaker that "tweaks" crash boxes.
Don