This short tutorial shows you how to create a static mesh from multiple brushes in UnrealEd. Some brush to mesh conversions result in the mesh lighting incorrectly, so keep it simple. It's recommended you use Maya (Maya PLE is included with UT2004 DVD) or 3ds Max for more complex meshes.
Create a shape using any additive and subtractive brushes you like.

Apply a texture.

Create a new cube brush, which is the same size or a bit bigger than your shape (so the whole shape fits inside).

Press intersect - this makes the builder brush take on the same shape as the brushes inside.

Right click the red builder brush and select Polygons > To Brush. The builder brush now contains information about textures used on your shape, so next time you use the brush it will have the same textures. At this point you can click Brush > Save brush as or Brush > Export if you want to save the brush.

Move the builder brush to a new location and press add to build it. You now have the same shape with no subtractive areas. Right-click the new brush and select Convert > To Static Mesh to make a static mesh.
(it's possible to skip the adding part and click convert to static mesh on the builder brush)
