There's nothing difficult about it, apart from the ***** ache.
You have to import all the topics into one project, fix all the links, rework the TOC, index and glossary etc. Getting the idea?
It seems odd to create a project with just five topics unless there is a very good reason. Are you sure you are familiar enough with what you have inherited to be entirely sure your predecessor didn't have some reason.
3,000 topics in one project should be OK but try to avoid too many in any one folder. If you also have lots of images then test things as you go. I have had more than 3,000 topics in a project but I have also seen people have issues with a smaller number but a high number of images (into four figures).
Perhaps do it in stages still having a merge but with fewer projects, see how that goes for a while and then amalgamate more.
See www.grainge.org for RoboHelp and Authoring tips
Thanks for the reply. Doesn't sound as difficult as I thought it might be (considering the number of separate projects). It looks as if 80% of the topics are already in one project.
I know the technical writer previously maintaining this system anticipated having assistance from other technical writers and thought it would be easier to have separate projects for individuals to work on. I also know the separate projects were designed for printing a complete document of each project. I will mark your first answer as correct. Thanks. Two follow-up questions if you have any thoughts on these. Is there a limit to the number of printed documents that can be defined within one help project? Since the .hhc file has "merge" coding for where each of the separate parts of the TOC need to be inserted, if I'm careful, is it OK to just cut and paste the .hhc files to make the TOC (and similarly create the Index by appending all the item name parts of the .hhk files)? Or am I better off just re-adding these items through RoboHelp? Again, thanks!