The lightmap problem was a show stopper for the project. Also, at that time sh5 was just over the horizon so it wasn't too hard to say goodbye to the old and hello to the new.
Unfortunately, instead of the birth a new sim, we got an abortion (IMO). Sadly, unless some miracles happen, I may never own sh5. I've also read statements/speculation of no further continuation with the series. This makes sh4 more important than ever now.
I would like to report that the lightmap issues are now solved!!!! 
Thank you vickers03! I was browsing this thread a couple of days ago and saw your post. If you had not posted that link I would have never starting tinkering again.
A big thanks to Nisgeis for his words of wisdom posted in that link. It ended up being a smoothing issue. Apparently, the game does not like multiple smoothing groups within a single element. I had most of my geometry welded together so that was corrupting the lightmap. Instead I had to detach parts of the model according to smoothing group into separate elements.
The project lives!
I will continue work on this project. I don't envision dropping the project again but as insurance I will turn over my work to the community if that happens. There are plenty of talented individuals here that could pick up the torch and complete it.
The next couple of days I will be putting the pieces back together. I have to clean the dust off and get by bearings again. I am in the process of going over my existing work and cleaning it up and improving it further.
I'll be posting some updated pics soon. Thanks again to all for your help and interest in the project.