Cupash? What If I made them in cupash but put the ones I made in Cupash in BrawlBox? Would there stilll be a limit?
From what I recall, if you place the files named, MenSelchrFaceB###.brres, into sc_selcharacter.pac or common5.pac, one at a time, there shouldn't be a problem. Here are some steps to keep in mind...
1: Run CUPASH and let it create your portraits.
2: After the portraits are created, go to BrawlBox, and open up either common5.pac or sc_selcharacter.pac.
3: Inside those files is a PAC archive called, char_bust_tex_lz77. That contains all the portraits.
4: Choose the BRRES archive that you want to replace. Once found, select "Replace" and go to the folder that contains the MenSelchrFaceB###.brres files; "menu\common\char_bust_tex".
5: Make sure that the number that's on the BRRES archive matches the first two numbers on the BRRES file. For example, Wario's portraits are in the archive, MiscData[37]. If you want to replace that archive with your modified Wario portraits, look for the file, MenSelchrFaceB370.brres.
6: Check the compression status of the BRRES archive after replacing it. The compression status has to display LZ77, since the archive is compressed.
I've placed as many as 160 portraits with that method, and my game manages to go to the character select screen without any issues.