The .gct file, the FitCharacterName and FitCharacterNameMotionEtc Pac files(As well as any other files in the "fighter" folder that aren't skins), the .rel files, and the common3.pac; there might be one or two other files in the system folder that are also needed for the physics changes, but not that I know of

 Why not? That's literally what that mods purpose is, they even add wave dashing, remove tripping, etc.

2 words: Project M

 Blender importing has gotten like 5 times better

You can take model A, delete everything in the Objects folder, export that as an mdl0, then in Brawlbox .71, open model B, right- click the MDL0, " Import New Object" or whatever it's called, use default settings, and click OK; it should basically merge the bones, so that, as long as the base hierarchy is the same, the additional bones should be added correctly

So, with the movesets, I'm not entirely sure, as I only attempted replacing all movesets with vBrawl movesets for 3.2 (Without touching the .rels), and Pikachu's Up+B was the only thing that didn't work right, but I haven't a clue for PM 3.6

With skins, Project M uses vBrawl bonesets, so you can place any (compatible) skin over a character (Including Lucario skins over Mewtwo and/or Marth skins over Roy; dunno about the other additional PM characters tho, since I never played past 3.5); I dunno about 3.6, tho, but with 3.5, there is a single bug with skins, where replacing Mario/Dr. Mario costumes, while any can technically work, if it's not a PM skin, it'll have the wrong texture on his Side+B

You know how, for example, Samus has that shininess to it? That's a "reflection" in 3d modeling

You can combine some of them with Gimp or Photoshop; technically, you can combine all of them, but if you want the reflections, I recommend not merging those textures with the other textures; does SFM natively support reflections, like Unity does?

Hey, everyone! I learned this information from two people: PrettyFlacko928 and also ALM5252, so a huge thanks to them!

But anyways, I originally consolidated the info from both of these people's tutorials into one simple text tutorial for my own uses for my project, Project Recolor, but I figured you guys might find this info useful, since everyone seems to have trouble with BrawlEx. So, without further ado, here's the simplest tutorial ever about how to use BrawlEx!

FAQ:

NONE YET

IMPORTANT NOTE: As Far As I Know, ONLY the Following Characters Can Be Cloned:
Mario, Peach, Link, Ganondorf, Lucario, Pikachu, Jigglypuff, Lucas, Marth, Ike, Metaknight, Wolf, Snake, Sonic, and Pit

Also, if you release a BrawlEx pack on BrawlVault, remind downloaders to use AxNextFrame Hook Type when loading through Gecko OS, or else it likely will not work properly!

HOW YOU CAN HELP: If you find that any of these don't work, please post here, or if you know how to get other characters working, please post here! I need your guys' help with this!!!

You can also help by providing general knowledge, such as how to .rel port characters to other characters for the regular fighters, because a lot of BrawlEx pack-makers might want to do this! I know I do!  



* = Do ONLY ONCE(If Doing All Character Adding Simultaneously)

In this example, I am naming the cloned character "Goku".

1) BrawlEx Clone Tool

   A) *Open BrawlEx Clone Tool*
   B) *Select the pf Folder*
   C) Add a Clone
   D) Write Down Clone ID(e.g. 3F)
    E) Change Clone Name to Desired Name(e.g. "Goku")

2) .rel Files

   A) *Open "_Rel Files"*
   B) Copy the .rel of the Character You're Copying into the Module Folder in pf
   C) Open the .rel in BrawlBox 0.71
   D) Open Section[8] in Memory Viewer
   E) Change the number that's immediately after the 3 '00's to the correct Clone ID(e.g. 3F)
   F) Rename .rel to "ft_charactername.rel"(e.g. "ft_goku.rel")

3) In the fighter folder, add a folder(e.g. "goku") for the fighter, and then add the necessary
   (Renamed) files in said folder(e.g. "FitGoku.pac", "FitGoku00.pac", "FitGoku00.pcs",
   "FitGokuSpy00.pac", "FitGokuSpy00.pcs", "FitGokuMotionEtc.pac", etc.)

4) Brawl Config Utility Tool

   A) *Open Brawl Config Utility Tool*
   B) *Open "CSSRoster.dat"*
   C) *Up the number 1 per character added*
   D) Scroll down to the bottom, click on the 00 Next to "Mario" and change it to the
      Clone ID(e.g. 3F)
   E) ***OPTIONAL: Drag and Drop Characters to Re-Order Them on the CSS***
   F) ***OPTIONAL: Use the Above ^ Method to Delete (Unused) Characters from the CSS***

5) Add CSPs and RSPs

   A) *Open the Sc_Selcharacter.pac*
   B) Export the CSP BRRES of the character being copied
   C) Import the BRRES, and change the ID to 110 + X, where X = the Clone Number
      (First One Starting at 0)
      (Example: 110 for the first clone, 111 for the second clone, etc.)
      ***(For simplicity, I'll call this [110 + X] the "Clone Number")***
   D) Expand the BRRES, and change the numbers in the names to (Clone Number)Y,
      where Y is the index(Starting at 1)
      (Example: For Clone Number(Character) 110, change MenSelchrFaceB.161(Marth Clone)
      to 1101, the next one to 1102, etc.)
   E) Replace the CSPs(As CMPR), and Change the Compression of the BRRES to ExtendedLZ77
   F) Export the BRRES, Open it in BrawlBox, and Change the Compression to None
   G) Place the Exported BRRES in "menu"->"common"->"char_bust_tex"
   H) Rename the Exported BRRES to "MenSelchrFaceB(Clone Number)0.brres"

6) Add New Portrait and Name Textures to MiscData[70] and MiscData[30]

   A) For MiscData[70], the Texture for the CSS Icon(CMPR) should be
      "MenSelchrChrFace.(Clone Number + 1)"
   B) For MiscData[70], the Texture for the CSS Name(I4) should be
      "MenSelchrChrNmS.(Clone Number + 1)"
   C) For MiscData[30], the Texture for the CSP Name(I4) should be
      "MenSelchrChrNm.(Clone Number)1"

7) Final Part with the Sc_Selcharacter.pac: Editing the pat0

   A) For MenSelchrCname4_TopN__0
      I) Card010
         a) Name = MenSelchrChrNm.(Clone Number)1
         b) FrameIndex = (Clone Number)1
      II) Card011
         a) Name = MenSelchrChrNm.(Clone Number)1
         b) FrameIndex = (Clone Number)1
   B) For MenSelchrFaceA_TopN__0
      I) Face02
         a) Name = MenSelchrChrFace.(Clone Number + 1)
         b) FrameIndex = (Clone Number)1
      II) Face06
         a) Name = MenSelchrChrNmS.(Clone Number + 1)
         b) FrameIndex = (Clone Number)1
   C) *Export MenSelchrFaceA_TopN__0 and Replace all of the "Face" pat0's below it
      (e.g. MenSelchrFaceB_TopN__0, MenSelchrFaceC_TopN__0, etc.)*

Replace the BPs in the folder for BPs

9) BrawlEx Cosmetic .dat Files

   A) *Open Hex Editor*
   B) Row 00000010, Column 00
   C) Change this number to a Hexadecimal conversion of the (Decimal) Clone Number

10) You're Done!

If anyone has any questions, comments, or is confused by my wording of something, please don't hesitate to comment below!  

 Try Brawlbox 0.71 for previewing

Also, not sure if Blender or SFM support materials with multiple textures assigned, so you might have to copy the polygon and change the texture for each copy

So, 2 questions: What version of Brawlbox, and is your goal to import this back into Brawl after edits and/or rerigging?

Just toggle wireframe and select various polygons until you figure out which one it is

Nope, it's not the same as the File Patch Code; the File Patch Code says to "replace" the data on the CD with what's on the SD card, and to use an SDHC card, you would edit the .gct file and add the code for making the Wii think that the SDHC is an SD; and yeah, he sent me the code, but I'm just too lazy to look it up, since he sent me a full pdf explaining how to use it with a more complicated thing that wasn't just relating to SDHC; there's also Google, if you're impatient and really good at searching

Unless I'm mistaken, compatibility is as follows:

2 GB or Less - Non-SDHC
More than 2 GB and Up to 32 GB - SDHC (Gecko Code REQUIRED for SDHC)

Do they even make 2 GB SDHC Cards, or Non-SDHC cards that are larger in size? I don't even think they do, except for possibly 4 GB, and even that, I dunno if they make 'em for that; also, this guy sent me some information about the code, so I would highly recommend contacting him for more info on it

His cape (If it's Marth's normal model) is actually  different polygons; did you delete all ?

Also, when you mention the "polygon deleter", do you mean the program from long ago, or do you just mean expanding the MDL0, expanding the Objects folder, right clicking the polygons and clicking delete?