The key card is technically supposed to come after you turn the power back on. That's how I usually play it.
Power > Then Keycard. If you turn the power on it's much easier to see everything in the security room.
If you're talking about the second power outage after killing the Baron, yes. I know. I specifically put waypoint markers on the keycard and reader so that people would be able to find it in the low light. (Protip: The Maintenance Keycard works on the opposite door as well, it just has no marker, because it's optional.)
As for the pickups: this is specifically why they respawn. So you're never stuck with absolutely no health or ammo. Even if you pick up everything in an area the stuff will eventually come back. The primary reason why I don't allow you to backtrack is because of the way the checkpoint system works. See, the default editor doesn't just allow you to set checkpoints. I had to build the entire checkpoint system and make it trigger resetting everything in each section by hand, and the only way for it not to break completely is to basically "wall off" the level as checkpoints are reached. It's a minor inconvenience but it was either doing it this way or making you walk through and entirely empty level from the first room to where you last died, every time you died, which is just annoying as fuck.
Also, it gives it a kind of Dark Souls type feel where you can't just kill a few demons, die and respawn and pick up where you left off. EVERYTHING resets when you die. All the monsters, pickups, etc.
Each checkpoint was meticulously planned out to cut off at a certain point that didn't feel like they were happening constantly, but also frequent enough so that you didn't feel like you lost a huge chunk of work every time you died.
Also, the red flash and the hurt sound when you take damage was custom made for the level as well.
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