When you export you're literally exporting a target geometry that differs from the default one & is a snapshot of the total history of that body part up until the time you created the morph, all the magnet work, shifted polygon groups, use of other MTs, dial twisting, whatever you may have done to change the geometry of the body part except use of posing parameters. Try this: create a temporary test character using a default head fresh out of the box, something off a content disk, anything you know is in a perfect, reliable state. Apply the new MT. If it works, it may mean that the other character you tried to apply it to has something in the head part that doesn't belong there. You may have picked up a bad MT when downloading from the net or the character's head got corrupted somehow. Apart from that, I'm clean out of ideas. Hopefully, someone else can think of some other cause.