I finally figured it out after 3 weeks of staring at 20 lines of code. It was all the ‘points’ part of the the position_material method. The instructions say 2,4,6, or 8 pairs of points. I tested the code on what I thought was the most complicated faces in the drawing, that being a spline like curve with a projected material mapping, which is really a series of faces with 4 vertices each. 95% of my drawing has faces with only 4 points. There are many that have more BUT do not have a texture map, then there are a few that more then 4 vertices AND a texture map. That is where the code failed and why it seemed to work on only sections of the drawing, the sections that had these textured objects that had faces with more then 4 vertices. I simply capped the points array at 4 vertices which still applies the correct mapping regardless of how many vertices the face has, what a pain in the ass.
476,352 faces, 7 minutes plus to make them all 2-sided, respectable.
Next up (and last I hope) taking a spline drawn in 3dsMax that has camera attached to follow, having it write a Ruby script of the position and angle of the camera at specified points along that path, then having Sketchup create all the scenes automatically.
By the way, back to my original question about a maximum limit. Sketch up has a mind of its own, if I import my entire project at one time, it will arbitrarily skip whatever it wants, its a joke, I imported the SAME exact 3ds file 5 times, each time it left out dozens of elements, I am talking boxes, not complex objects or whatnot, and everytime it was different. Sometimes one element came in, then the next import, it was gone, then it came back, etc. etc. it was funny, I was showing my boss this because he insists on using Sketchup so he can walkthrough buildings with his clients. Any thoughts about why it does this ? It is remedied by turning off about a third of the layers and importing 3 separate files.