The collision avoidance code in Dungeon Builder isn't perfect...it's just an approximation of "real" collision avoidance code. The real thing would use a movement sphere and check it against every polygon that intersects it...I have code elsewhere for that, but for something like Dungeon Builder it isn't really necessary. When you export your zone to .S3D the client will use its own collision avoidance code and you should be fine.
If you have any walls where the texture wasn't set yet, Dungeon Builder's engine tends to use the last texture loaded. It has to do with the way the 3D engine was implemented, and basically it doesn't unbind textures if there is none: it merely uses the one that was last bound. When I build dungeons I usually first click Edit...Set all dungeon textures to make sure that every wall has something assigned to it. There is a checkbox in the dialog box that pops up that will preserve any existing assigned textures so you won't lose any that you have already set. Once I've done that, I then click Edit...Set individual textures (or just click the toolbar icon) to change walls one at a time.
When you export your dungeon, Dungeon Builder will warn you if there are any walls that don't have any assigned textures and will color them either red or blue in the .3DS file (it's red for walls or blue for ceilings and floors, or vice versa -- I forget which). When you import the dungeon in OpenZone, they will be apparent. I should probably get Dungeon Builder to do the red/blue thing when you are walking around your dungeon to also serve to tip you off about unset textures. I'll take a look and see if it's possible for 2.0.
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