Could you please post the following screen shots.

 

Load P6 James and the flight suite. Do not conform but fully zero both figures.

The Wardrobe Wizard conversion window showing your selections, options etc.

P5 Don and the converted flight suit. Do not conform but fully zero both figures.

As (3) but conformed.

When zeroing a figure ensure that absolutly everything is zeroed, translations, rotations, scaling (100%), morphs. Later versions of Poser have the menu option Figure > Zero Figure. Or use the Wardrobe Wizard "Zero Figure" button.

Thanks.