NOTE: If your car is a stock car repaint, you'd rather want to use one of the default shadow presets than generating your own. In that case, you can skip the first 3 steps and go directly to Step 4.
Step 1: Generating the shadow
In Blender, press 'A' to select all objects and remove them using 'Delete' key. Go to 'File -> Import -> Re-Volt' and open the "Parameters.txt" file of your car. This will import the entire car into Blender. All objects should be selected by default (note that shadow will be generated only for the selected objects).
Select the "Object Data" pane in the Properties Window (the triangle icon right pane). See the picture below to locate it.
You'll find the Car Shadow Maker option by scrolling down to the end of this pane (see below picture). Use the 'Create Shadow Polygon' option which would, by default, create a 64x64 texture with a 4 pixel margin (more on this later). Then use the 'Soft Shadow' option, and finally 'Bake Shadow'. This would generate the required shadow map. There is one more option in the Car Shadow Maker panel called 'Get SHADOWTABLE' which you'll use later.
Step 2: Retrieving the shadow texture
To retrieve the generated shadow texture, press 'Shift + F10' in Blender to open the UV / Image Editor. Use the "Browse Image" option (highlighted in the picture below) and select the "shadow.bmp" texture from the popup list.
You'll notice that the shadow is black on a white background, while Re-Volt requires white shadow on black background. You could invert the colours right in Blender, or you could do it later in your image editor. For now, press 'F3' to save the image - the default format is PNG and it can be changed if required.
Step 3: Processing the shadow texture
Now that you have your shadow texture, a little bit of post-processing is required to get it in Re-Volt format. So open up the texture in your favorite image editor such as GIMP.
The first step is obviously to invert the colors to get a white shadow on a black background. As mentioned earlier, this can be done directly in Blender but most car designers would feel more convenient using their own image editor. In GIMP, this can be achieved through 'Colors -> Invert' menu option.
The second step is to apply a little bit of blurring to take care of any aliasing and noise in the texture. A 2-pixel blur should be more than enough for our purpose. In GIMP, use 'Filter -> Blur -> Gaussian Blur' menu option and set both the Horizontal and Vertial Blur Radius to 2px.
And then you're done. Be sure to save the result as BMP. In GIMP you can just use 'File -> Save As' and directly change the file name from "shadow.png" to "shadow.bmp". Picture below shows the original shadow generated by Blender and the final one for use with Re-Volt.
Step 4: Setting up the shadow
This is the last part of the walkthrough. Now you're going to update your car's Parameters.txt file with the following entries to finally add the shadow.
Set the TSHADOW parameter to the path of your shadow texture. This works the same way as setting the TPAGE and TCARBOX parameters.
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;)SHADOWINDEX 0;for RC Bandit shadow
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;)SHADOWTABLE -39.3 39.4 66.7 -68.2 -5.0
Click here to see final result in Re-Volt, on Stealth XB by hi-ban.