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I'm attempting to create a t-junction hallway but can't find a nice clean way to do it. Seems like everything I've tried so far results in bad faces and stuff that I know is going to cause problems on export. The problem is cutting a hole in the side of the main tube for the offshoot - I can do it with a boolean difference but then I have to drag the vertices to match the curvature of the wall... it gets messy. If somebody who knows what they're doing could help me out that would be awesome

1) Do a boolean union. 2) Freeze both and delete or hide the old object so you only have the united one. 3) Select the edges where the two tubes intersect. 4) Bevel the selected edges. 5) Adjust the distance and rounding settings as needed. 6) Clean up the excess edges at the start and end points of the bevels.

What are you using for the pre-union polymeshes? I must be doing something different because I have this after my union:
I'm having a hard time cleanly getting those extra polygons out of the hallway.

Edit: Nevermind, I got it. I was using two cylinders to give the tube substantial walls, which added lots of complicated edges. I'm following through with your instructions now