There is an inherent limitation in all Quake 3 engine-based games. It has been raised in Quake 3 and RTCW, but I doubt any of the licensees have addressed it, as it hasn’t shown up in their games.
Lightmaps are stored as 128x128 pixel textures in the BSP file. Every texture or shader you use in your map that is lightmapped gets combined with the lightmap that’s used to create an internal shader. Due to the way Q3Map2 projects and stores lightmaps, this can result in a higher number (25-50%) of internal shaders. This is the side effect of Q3Map2’s higher lightmap efficiency (25-50% fewer lightmaps).
To test if your map has hit this limit when compiled with Q3Map2, run the map in SOF2, bring down the console, and type /shaderlist. It will list all the internal shaders, including all the lightmap/texture or shader combinations created. Check the final count at the bottom. If it’s higher than 1024 (or 2048, not sure what SOF2’s limit is) then the map has hit that internal limit.
To get around this issue, you’ll need to force the map to have less lightmap data. Use _lightmapscale on func_groups of sets of brushes where shadows are less important. A value of 2.0 will result in 1/4 the lightmap data for those brushes/patches.
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Edit:
Der…2.0 not 0.5 