I have been trying to create a different shirt for the Sammy Toon Kid model by creating a conforming clothing item. When setting up the shirt I use the bones from the original figure. The making and boning of seems to go okay but when I actually select the "Conform to" function under the Figure menu the result is as pictured.

1. Immediately prior to conforming I check the stetup of the new shirt (- the original model includes the upper arms in the shirt sleeves so I have of course included them in the new shirt.)
2. After the conform the resulting model looks like this. (I unchecked the visible box for the original models chest, abdomen and left and right shoulder sections so only the new model sections are visible.)
3. Immediately after the conform operation I check the setup for the clothing item and it is inexplicably altered. WHY?

I'd really appreciate if someone can give me a few clues on what might be going wrong. I've been through the process half a dozen times including remaking the shirt object and the result is always exactly the same except sometimes the distortion twist occurs on the opposite side of the body. Previously I made a pair of shorts for Sammy and there were no problems of this kind at all.

Did you zero the joints?

When I do shirts I include a dummy neck and head. Need not be any actual geometry, just the body part lines in the CR2 file. This then appears to keep it all lined up.

This in addition to what Little Dragon wrote.

Thanks PhilC and Little_Dragon - I'll try both suggestions. Another thing I've noticed is that even though I line up the shirt object so that it is in the correct relative position with the character before I go into the setup room when I selct the characters bone structure it is displaced in the y axis by about .005. Don't know what is going on there.

The bone structure is probably displaced because the character's yTrans value isn't zero. For some reason, a lot of figures are like that by default. I prepare the donor figure beforehand. That means disabling IK, zeroing all the joints (with the Joint Editor), making sure all the trans values for Body and hip are set to zero, and memorizing these settings (Edit menu --> Memorize --> Figure). Once this is done, save it to the Library and then load that in the Setup Room for your bone structure. You might also want to strip all the morphs from the donor figure, by hand or with Morph Manager, since they probably won't be compatible with the clothing mesh you're poserizing, and you'd have to remove them afterward anyway.