Seing a lot of potential in Tyler, but having no luck making a new face.  I tried once using both head shapes and a magnet, but when the morphs were zeroed and the magnet deleted, my new morph was horribly deformed at full strength.  Tried again just making a few small adjustments, and again the morph sucked the face in when applied at strength.  Normally this means that a morph(s) hasn't been zeroed, but I've went through them all several times and can't find any in use.  Is there something different with this figure being a re-sculpt?  Could the body morphs be affecting the face?  Is there still even a point to creating a custom character face morph if the face shapes and expressions have been separated?

Here's probably where you're going wrong: You have Tyler's face still active when loading your morph. If you've made a morph from Tyler you're making a morph from a morph, so you're going to end up doubling the effect. Turn off Tyler's head morph (if it is on) and dial in your morph. 

If that's not the case, then I don't know....we'd need to see screen shots.

I am spawning a morph, not loading.  I just can't can't find any un-zeroed dials that could be causing the problem.  When you say Tyler's face is active, do you mean the Tyler morph is at full strength?  After spawning the morph I set all dials to zero.