Here is the latest update:
http://www.threewaystudios.com/xfer/vorchan_10.jpg
http://www.threewaystudios.com/xfer/vorchan_11.jpg
http://www.threewaystudios.com/xfer/vorchan_12.jpg
Only the head section and the intake boxes were modelled as SubD (and then frozen and optimised a bit)... everything else is just conventional poly modelling. I find its easy to fall in to the trap of building everything SubD when it doesn't really need it.
I'd quite like to know exactly what the 'boxes' on the wings are for. They look like they should be air intakes, but I don't think they would be.
Cheers!