Cool! So glad that you are liking Art Of Illusion. I like it a lot too! Did you start this from a cube? Can you post how this looks in the polymesh editor in edge mode? I'd love to see the vertices/edges. I'm planning on making a head myself one day. This is the tutorial I plan to follow: [link] and here are the rest of those tutorials: [link]
When you have your model in (approximating) smooth mode, did you know that you can go from smoothed mode to unsmoothed by using the shortcut key s? I do that frequently. Here's another tip -- See this to add a shortcut to view your entire scene (when you are putting multiple items together to create a scene) : [link] .