Ok so I have gone back in and think I've found a slicker way of doing this. (I've also ordered my 3D printer)
I am using Flying Squirrels pep helmet file as a jumping-off point.
I got to thinking about what my goal was, which is to smooth the part of the model that usually are sanded down, but leave the hard angles intact. I tried to find a way to 'lock' the faces and vertices and have the subsurf modifier leave them alone. What I stumbled on in my Googling is to select every 'hard' angle that I want to preserve, and "crease" it to a value of 1. Before, I was dividing the model into each face I wanted smooth, which resulted in one object for each face. When I crease the edges, I am not splitting or otherwise dividing the object in any way. Once that is done, the subsurf modifier is unable to alter any edge that is creased.
View attachment 14095
As you can see, the left side has been smoothed by the subsurf modifier, while the edges I designated as creased remain unchanged.
View attachment 14096
Here you can see where the angle 'indent' is intact, but the back top of the helmet got smoothed out and greatly improved. I'm going to tinker with it a bit more to see what I can do. BUT the best bit, really my favorite bit, is that since it remains as one object, the model stretches to the crease, and no gaps form as a result like at the corners with the hand plate. Just wanted to pass it along, and once my printer arrives and I get it calibrated and a few test prints ran off, I can start chunking this model and printing the helmet and other pieces. I hope.