Do you have any tutorials on how to replace a character model like you did? Not replacing with a PSA or anything, but trying to replace a character with a model I got out of Tatsunoko VS. Capcom (followed this tutorial, but did Ryu https://www.youtube.com/watch?v=bePnCJ1hRlk ). I assume I'll have to edit the model (has multiple hands and multiple layers for the character that where probably used for shading and not needed) and rig it a specific way. I use Blender, but I'm open to 3DS Max since it looks like it's what used for this process. 

Using Roster.dat instead of the GCT merge stuff, still having issues. Seems to have found the problem though.   

Tried to use another character to clone (Lucas) and noticing it's defaulting to Mario's icons ( http://puu.sh/kbIvG.jpg ) so it probably is a problem with the character's files, but I have no idea what. I've redone this ( https://www.youtube.com/watch?v=UoWad-wuqFs ) tutorial at least 5 times, and I just tried this ( https://www.youtube.com/watch?v=0QHtHbJL79M ) tutorial twice (although I had to do the method in the other video for the files since every download for the Clone Tool is broken). 

hm, I'm confused then. Followed the video again and still having the error. Here's my process:

1. Download your GCT file and inject the CSS code ( http://hastebin.com/ozikuhekas.md ) into it using GCTEdit.  
2. Create the BrawlEx folder in the pf folder, and fill it with the 4 needed folders.
3. I use the default 'module' folder from PM (I do put bx_fighter in this folder), and I use the default 'System' folder from PM but replacing 'common2.pac' with the one from BrawlEx.
4. Copy the 4 files needed (cosmetic/fighter/slot/CSS) into the needed folders (using Mario's files as a base), rename them.
5. Edit the 'fighter3F' file, name the fighter 'MarioEx', set Kirby to 'None', save the file.
6. Copy the module from BrawlEx for Mario, edit it to have the id of '0x91', edit section8 to have '0000003F' and save
7. Setup file stuff ( http://puu.sh/kauRn.png ).
8. Do the gekko and emulated SD card stuff, run boot.elf  

Results in http://puu.sh/kavhw.jpg (one is Mario, the other is MarioEx).

Can you be a little more specific? what kind of errors are you having?

Hey, I tried this for 3.6 and I have a question.
The game seems to load the character fine and such, but as soon as the match starts (when he says 'GO!') it crashes. Any reason why this is happening? ( http://puu.sh/k0syy.jpg )

Thanks for any help!

Having this error and dunno what it means.

Hm, I didn't change anything with the cosmetic file (except for copying CosmeticMario.pac and renaming it) and I'm still getting errors.

Hey, I tried this for 3.6 and I have a question.
The game seems to load the character fine and such, but as soon as the match starts (when he says 'GO!') it crashes. Any reason why this is happening? ( http://puu.sh/k0syy.jpg )

Thanks for any help!