Any help and tips would be appreciated! If more information is needed just say the word and I'll edit the post, etc.
Blend4web has a tool called Normal Editor. It has a feature, that may help.
It makes custom vertex normals based on nearest vertexes:
After this operation blender creates custom vertex normals, and if you change something in geometry normals will not update, until you not delete custom normals. To delete them goto mesh settings and click this button: