Actually something has just occurred to me......

The offending characters so far have been Sydney and James 1, these are both CRZ files. The characters that I have tried so far that work OK are David and Apollo Max, which are both CR2 files.

What does anyone think ?

FWIW, I don't know how to convert a CRZ file to a CR2 file, I know it can be done.....it would be a good test to see if I can convert Sydney to a CR2 and then see if she performs better with the morphing brush .....