"Seems like you may have line polygons that are invisible to the naked eye and UV mapper."

I think that was my problem.  I used auto grouper and it seems to have worked itself out, aside from the fact that somewhere in the process I moved the boxers, so when all was said and done they weren't positioned correctly on him.  Oh well at least now I know the model is grouped right, just have to re-bone it.

Thanks for the help and ideas!

I am:  aka Velocity3d