Ah, well it's definitely not the first one since I have nowhere near 32 vertex groups (and deliberately avoided that), but the second one looks on the mark. I used the version of the export script from the first post in the thread, which I think is out of date since it clearly doesn't do what he says in the second post (and dates to February). I'll try rewriting to match his new version of the script and report back.
EDIT: Actually, it does look like I had the new version, since I do see something about 255. Doesn't seem to be working though after I rewrote for 2.71. Let me look through it...
EDIT2: Ah! No I didn't. There's several more lines in the new script that enforce the 255 weight that I didn't have before.
EDIT3: Well, progress. The warping is gone. However, something still appears wrong in Nexus:
It looks like the mesh is glitched such that there's a giant part of her back that's missing...but this doesn't show up if I open the gr2 in granny.
And if I try it in civ 5, giant glitch texture is still there:
I've tried playing with the scaling, to no avail, and direct size comparison between this unit and, for example, the antiaircraft gun, shows that she's about 1/2 the size of the gun, so there's no reason she should appear as some sort of full-screen giant.
EDIT4: And just to rule it out, I've tried scaling it down all the way 0.0001, and replacing the current 2048x2048 texture with a more typical 256x256 texture. Neither of those do anything. Having no texture at all just causes a giant red/white texture glitch. I'm going to take a break for now...
I didn't figure it was the first one since I only saw 3 vertex groups in the mesh, but not having a complete picture I didn't want to rule it out. I still have problem units myself, so this may be yet another unsolved anomaly.
I have one more suggestion, and it could be valid since a) you mentioned you worked on this in a later version of Blender and b) There are parts of the mesh missing in Nexus. Have you checked to verify that the mesh doesn't have any n-gons? Only quads and tri's can be converted, so if you have pieces of mesh that have more than 4 sides (including a tri or quad that has a vertex along an edge with no connecting edges) then I can see this problem occurring (this has happened to me before). Hopefully this is the culprit.
If not, this sounds like a job for: The Deliverator!
