What I read somewhere reading from EPIC direct, don't touch the slider. Pretty much from Unrealized (now defunct unless there was a rehash, check the webarchive)
I sometimes do rebuilds without doing BSP, this is done on some trooublesome maps where doing BSP starts making bad cuts in geometry.
Untick Optimize Geometry to try a few things. Building Unreal maps has always been tricky especially when you want to do some little more complicated geometry.
Some mappage may be better when you check on build priorities, putting an object in first or last of the build process, this is the difference of seeing if 2 crossing timbers overlay each other, one might texture overlay the other depending on the build order.
A subtracted room is first in the order, added objects follow, lets say you first ordered a box in a room, that screws the rendering order and looks like crapola.
Try to keep mappage simple and points landing on grid areas as possible, that helps cure BSP holes, I usually don't go lower than 4 on the grid setting.
But sometimes there are circumstances I have to go under, its a test and try and see if it works.