Hi,
I think what you are trying to do is really reproduce the marching cube algorithm. I'm pretty sure that it was indeed used in the NoCubes minecraft mod but in a very old version.
The reason it would give a very constrained look with the "rules" you described in your other post is because the "density" used by the algorithm is really an average of the binary data over the surrounding block. Basically if you had smoother densities with your marching cube algorithm you could have a truly smooth terrain, but here we only have the "full" or "empty" information for each block. This gives the peculiar slopes.
There is an implementation of marching cubes in Cadiboo's version of NoCubes. I think this could be fairly easily rewritten in VS and I plan to do it.
At the same time I'm working on a simple mod adding finer density data to blocks. The idea is that it could be used, among other things, to render even smoother terrain that could be dynamically changed. The inspiration I have is the 7 days to die voxel engine.