Good to see you back mate...looking bloody exceptional as always my friend. Having had the same problems I usually forgo all the bullshit and bevel as much as I can. When it comes to corners Maya does like to create pain...as you said creates seams where you dont want them. I have also used the split poly tool and stop my lines short of the opposit edge, this of course also creates wierd vert warping...painful stuff.

Good luck with it mate...I will be watching intently

Cheers bullet