Thanks dunkelzahn for the input.
Here is a few more details:
-This model is a human body scan.
-The model is one whole mesh with the body and head uv mapped separately.
-verts 17108 14279
-UVs 20178 16929
-142 joints with 109 degrees of freedom that we use.
Why so many joints? We are building this character for our own realtime app and apparently our app requires a single joint for a single degree of freedom, i.e. the shoulder has three degrees of freedom = the shoulder has three superimposed joints. Don't ask me why this has to be this way, it just does. Now you know why I don't want to paint the weights on this again!
As far as your suggestions, here is what I have learned so far.
-If you duplicate your model using geometry type "copy" and group under "world", you get two versions of the same geomety with the same names, except for the top group node.
-Poly count remains consistent.
-As far as I can recall, no UVs have been altered since skinning.
-No ploys have been moved
-There is history on this surface, and both settings for "Delete Non Deformer history" destroys my skin weights.
I believe the last one is the problem. Is there any way on earth to get rid of surface history without destroying skin weights? ( plugin? mel script? ) I could avoid the problem entirely if there was a way to freeze transforms on a skinned joint. ( plugin? mel script? )
Im really beginning to feel that Im outta luck here.
Suggedtions? Comments? Lifelines?
Thanks