"Check to make sure all your vertex are actually welded and it has the same number of vertex in the mesh. I have been using it for years, you are too quick to give up. Also is this thread for morph fixes in Poser as stated or for maya and lightwave?
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When I export V4 from P6, the vertex count is 69759 whether the mesh is exported as "welded" or not. The differences are that the welded version replaces all duplicate vertices at group boundaries with a welded vertex plus a free vertex. Thus, the welded version has 2140 more vertices than the original V4 obj file.

The only options I can think of are:
blMilWom.obj as Original, welded export as Morphed
blMilWom.obj as Original, welded export with unattached vertices deleted as Morphed
blMilWom.obj as Original, welded export with unattached vertices merged as Morphed

None of these works. Morpher seems to really want the split/unwelded mesh as the reference.

The issue of export came up because my ideal workflow is to add morphs and/or poses in Poser, export the obj, massage the obj in another application (LW,ZB, and/or Maya), and then generate a FBM based on the original mesh as reference and the massaged mesh as the target. This requires that the original and massaged have the same vertex order/number. N.B. I'm not saying this is the only workflow, just my ideal one.

I really do appreciate all the suggestions. I'll try the layers in ZB later today!