Caveat: I don't know a lot about rigging. Having said that -

I think the purpose of Merge All Zones is so that you could use the older method of spherical/capsule falloffs first to get started (as they can be quicker for an initial pass), then Merge and then refine the weights. Also used for converting older figures to use weight maps.

With the second problem, if you export the figure as an FBX format file with the rigging options checked, does it save the weights? Can it then be imported with the weights intact? Reason I ask is because this is supposed to be a good way of transferring rigged figures between apps, and I have been able to load La Femme in Lightwave with the rigging intact. Thought it might be worth a try.

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