I didn't post the blog yet (tonight

) but here are the main ideas. I'll add a link to my blog to my contact info. I've been meaning to do that.
Tips for importing laaaarge legacy Word docs:
1.Created the project. Added the files that are common to all of our team’s projects, kept in a master project. Example: the preface of the user manual.
2.Created the folders in the Content Explorer prior to imprort. These folders mirrored the structure/TOC of the legacy content.
3.Divided the legacy manual into separate Word documents. That way the topics created by each import could be easily sorted into the CE folders.
4.Prepare each document for import – you may want to remove cross-references, page breaks, section breaks, logo pages. You can test-import a document or two to see what doesn’t come over well.
5.Created a CSS with styles that corresponded to the styles in our Word template. Saved us from having to design a CSS from scratch. I hear you can do this by importing a document and create a CSS based on your Word styles. I don’t think this is what our CSS guy did, though.
6.Mapped to those styles during import.
7.Post import editing – imported lists all had to be combined, imported tables didn’t use table styles, many links and cross references were broken, many of our images were stripped out or placed in the wrong location.
8.Created TOCs that mirrored the structure of the imported content-quick turnaround for first iteration.
9.Formatted each style for online and print. (Arial vs. Times, indents, etc.)
10.Retained heading numbers – headings 1-5 formatted the same online, differently for print. Helped us to easily reassemble the manual.