Hello d-larsen,

this is also my experience, that Poser can behave very
odd from time to time when it comes to complicated
modelling. Or even sometimes with simple modelling.
I still have a character whose hair goes away sometimes.
In this case if I render it, is goes
back into the correct position.

Anyway, I'd say one should make security copies of every
step, like saving it as pinhead01, pinhead02 and so on,
and keep all theses steps for several days until you can
be sure that the last and final stage always works
correctly (posing, rendering, morphs ...)

And additionally, it could be a good idea to do
complicated modelling with some external software.
As far as I remember, this takes the following steps:
save the raw character somewhere in your library,
let's say as pinhead_raw01.
Then you export it as obj, import it
somwhere else, make all the changes and export it again
as obj.
If there weren't too many changes (like global scaling,
rotation, removing body parts) you can use the new geometry
with the old "skeleton" to get the complete figure:
locate the pinhead_raw01.cr2 file, open it with
wordpad and search for the references to the geometry
(there are 2 and they look like
figureResFile :Runtime:Geometries:ZygotePeople:blMilWom.obj
) Change the path to your new geometry and hope that
this worked ;-)
If not, import the new geometry into Poser and see how
it looks like. Maybe you must scale it or something.

Good luck,

Ernst