This hack was deleted for an incorrect reason, the person did not see the (PSA ONLY) in the title and reported it for not having a texture. I use it and it also does not freeze.
Original Post
http://forums.kc-mm.com/Gallery/BrawlView.php?Number=23254
Here is a download link for it.
http://www.mediafire.com/download/n5e1ehqorep7nff/Galacta+Knight+PSA+%28PSA+only%29.7z
The person who reported it obviously does not know how to read the title.

I have a question to ask the general population. Has anyone managed to squeeze an extra 12 character slots out of the boss files? Also, has anyone found a fix to slot 58? If so can you say how?

Most likely the problem is your common5.pac/selcharacter.pac are too big.
The size limit for the selcharacter.pac is 3.79mb and the common5.pac file size is 11.6mb.
To reduce the size just re-encode ur csps to CMPR when you replace them.

Hope i helped!

if you have been modding for over 3 years, u should be able to fix it urself

Which i am 90% sure i know the problem. I am pretty sure it is my sd not my mods and i was just posting to see if anyone agrees... i didn't mean to sound rude.

Sometimes my ssbb will freeze when i load up the game. This is very odd because i have been modding for about 3 years, yes my files are named correctly im not a retard, and my info.pac is under the size. The p***es me off because i have to get up and turn off my wii every other time i go to play, which is alot btw. I have just about no clue what is going on and if anyone can help thanks in advance.

P.S. This is a very difficult to solve puzzle because it most likely is not an obvious fix. Do not tell me that is is because oh, ur file is named wrong. Because as i said IT WORKS EVERY OTHER TIME. So, one day it will load up just fine but the next, nope it froze and i have to try again, and it works. So again, thanks in advance for responses.
 

https://www.mediafire.com/?gxms06929aar668
There you go reduced the size.
All you have to do is reduce the stage preview pics to 88x88 and change the image format on the icons to CMPR. I only did a couple so if you would like to reduce it more have fun.

It's not coming from the PSAs; just turn off the results .pac in the FighterConfig for now.
Gray Fox doesn't need it anyway.

Alright thanks so much i tested it and it works. I don't know what i would have done if this help forum wasn't so, well helpful. 

Thanks again.

Do you have them named as FitMetaknightCharacterResult.pac or FitCharacterResult.pac?

FitCharacterResult.pac

So recently i started using a few metaknight clones for my brawlex hacks. For some odd reason the two metaknight psas, (Gray Fox and Galacta Knight) Freeze every other match before the results. I checked my Stg_result and there was no problems there and both of their after brawl portraits, (Under menu/common/that other folder name) were not compressed and named properly.

I am pretty sure that the freezes are coming from the FitMetaknight(Grayfox/Galacta)Result.pac. If anyone knows how to either fix and or not use these files your help is greatly appreciated.

This is annoying I really want my mk clones to work  

Do you have result portraits for them?
Find the slot their in for the CSS portaits (eg. Mario=0, Link=1 (IIRC), etc). It could freeze if you are missing results portraits or if the portraits in there are compressed.

If you didn't know, the portraits arein pf\menu\char_bust_tex.

Thanks for the reply. See thats what i had thought was the problem but i had that working. The thing is one match the same exact characters will work but another they will freeze.
(E.g.: Match 1: Naruto vs Gray Fox, doesnt freeze. Match 2: Naruto vs Gray Fox (SAME COSTUMES AND EVERYTHING) Freeze...)
i don't understand anymore i honestly tried everything and triple checked all the files to do with the result screen.
If u have any idea what is going on here feel free to respond.

Occasionally after a match with some of my added characters there will be a very quiet buzz and it is stuck. This only happens after for example a match with gray fox and naruto. Then, i play another match with them and it doesn't freeze... This is really annoying because every 5 or so matches i need to restart. To whomever replies to this, thank you for your support.