I still don't quite understand what you are asking

If you only want to display the damage face, just hex bone index like last time.

You can do it by hexing the bone index to make it visible all the time... I don't think renaming facepattern bones would do anything

I guess he means as if painting a sculpture.

Though it would be very useful, I don't think there is anything that does that

Apparently, hexing one to appear permanently can cause problems...

If you are using 3dsmax+Mariokarts method, I'd suggest using the Morpher tool to change all the other faces to the one you want, then export them individually

Turn the volume on your tv up

C'mon peoples, Don't you think we have enough Sora's???

We need more Dizzy!

Texture is incomplete but...

Can you guess who it is yet?
                                                                                                                                                                                  [/aussie accent]

Snubbull or Nuzleaf

Demiveemon

Disabled bone aren't likely to be the problem, It's probably the deleted polygons that causes it.

Hex the vertices over onto a 'clean' model.
Now, instead of removing the polygons, remove the unwanted vertex sets instead

Still needs a little work in my opinion.
It doesn't need alot done, but I'd make the face wider and shorter...

Use his Manganime appearance for reference:

(the reference you have may be from an actual One Piece game, but it looks awful )

Looks like the school uniform from Clannad...

Here is the 30 day free trial for 3dsmax8.

Ms.Spinda made a tutorial on how to vertex hack with anim8or.
I'd check it out if you don't want 3dsmax
Here him am

If the two parts are close together, you can just rename the bone to match the one you want it to follow.

Otherwise you'd have to re-attach the polygon altogether.