Re: Modeling a human... and a question
The modeling here looks very good.
To ensure you get a seamless join, make sure you perform an "Optimize vertices" (I notice you mentioned "Optimize surfaces" - make sure you hit the vertices as well).
If you have done this and still get a seam, check the AC3D manual for the topic "Snap together by distance". As the description reads:
"If Object->Optimize Vertices does not remove duplicate vertices then it means that the vertices are in very slightly different positions. The solution is to select the vertices along the join and Vertex->Snap Together by Distance. The Object->Optimize Vertices will remove the duplicate vertices and allow the surface to appear smooth."
HTH
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