Re: code, I really don't think that cycle pinching is the main problem — I think it's algorithmic. I'm going to need to think about that a bit more. At the minute I'm a bit indoctrinated as to how I think a 3d pipeline should go, and I may need to rethink that.
Sometimes you have to take the unconventional route when optimising for "old-skool" hardware! Textbook methods are fine if you have the horsepower - if not, then you'regoing to have to look at pulling out all the tricks you can. :-)