I can't add much to the other thread, really; except to add to their efforts to steer you away from the setup room. PHI builder would be a better starting point, in my relatively inexperienced opinion. I do know that the setup room can group your mesh for you, but I thought you had to ask it to do that. All of the advice I've seen suggests that you shouldn't let the setup room anywhere near your grouping. It may be that it's confused by some feature of your mesh, and is trying to be helpful in that annoying way that Microsoft has. If you haven't already, try opening the grouped mesh in UVMapper; maybe have a look at the grouping, to satisfy yourself that it IS as it should be; then save it out again without doing anything to it. UVMapper can straighten out many a dodgy mesh. If you have UVMapper Pro, it can be helpful to select by group, then twirl around the 3D viewport to see what part of the mesh really belongs to that group. It can also highlight things like degenerate facets that can cause trouble. I'd also second the recommendation for STOMP that was given in the other thread. Finally, if you want a second pair of eyes to look for oddities in the mesh, I promise not to fold, mutilate, spindle or sell anything you may choose to send me. ;) I can't help much with the actual poserisation, though, since I generally make conforming clothing, and that's much easier.