Quote: "It's the zbrush model you'll have to worry about. It will be very tessellated. Depending on what you do, it could come back into max in the millions."
I'm not totally sure what you mean will be the problem about it. If you mean the sheer amount of polies than yeah, I'm with ya. And it's funny you mention it, but just the other week pixologic gave us this new decimator for zbrush that gets rid of polies while keeping as much detail as possible. (pixologic, the creators of zbrush are literally one major street down from my school) Unfortunately we can't use it yet, we have to give the file to our program director who'll decimate it because they made him sign an nda and whatnot.
As for baking, we have a really interesting tool in maya (I believe it comes standard) that takes high poly geometry and places it on a low poly mesh as a normal map. I'll put together a lil' vid on it to give you an idea it's pretty funny to see.
Here's tonight's progress: HW due for tomorrow is finish off the head minus the ears.

(red marks show where I want to bring in the nose)
P.S. I'll definitely check that program out Sid