I put up a series of videos on my site that follows through as I design a model in Rhino:
Murph's Models - Videos
I dunno how helpful they'll be, but they show exactly what I do. I had to stop the videos before I finished the model, because recording was slowing me down, and I had a deadline.
One thing I do when designing in order to get parts edges to line up, is I design it as a paper model.