I model some thing simular but it does not matter how you model its the end result is, box modelling or extruding edges at the end you are going to need to have good edge flow and a clean mesh (not ngons and no tri`s if you can). Soften norms is under normals in the polygon menu, this would be used when you are not smoothing(3 button or adding mesh smooth) the mesh but want smoother there is also a option to harden a edge, I think there is a little tutorial by ctbram in the free friday tut.............dave