Okay, it sounds as though the original Dork isn't completely welded (if you weld him you remove vertices). Thinking about it, this could be something to do with the geometry switching used on his hip. I've often wished for a UV map copying utility that would cope with dissimilar meshes, but I don't know of anything. Is it just the head that you remapped? If so, I have an idea of what to do. Let me know and I'll try to come up with something.