Ok so I've only just decided on trying my luck at KOTOR 2 modding. I'm using 3ds Max 8, and the latest tools (NWMax, MDLOps, Kotor Tool). I have gotten as far as modifying an existing KOTOR 2 head and getting it ingame:
** It appears I needed to use headfixer which fixed my position problem. **
Is there a solution to not needing the hard edges matching the uvw islands for the textures to not render skewed?