It seems to actually cause the freeze even without the Fighter Configs for expanded costumes. Unless that's just me, which would seem odd.
Unless it's ANY character using the fighter configs for expanded costumes, then the question of "How does that work?" comes up.
had you ever looked luigi or yoshi fighter config with HXD?, if you take a look, you will Instantly know the reason of Luigi and Yoshi freezings,.. as I said, this is a fixable issue, ..
and I must add that it is not related with expanded costumes
EDIT:
Well I will Explain
this is Yoshi fighter config..
46 43 46 47 00 00 01 00 00 00 00 01 00 00 00 00
02 00 00 17 00 00 13 FF FF FF FF FF 00 00 00 08
00 00 00 4B 00 00 00 00 00 00 00 00 00 00 00 00
79 6F 73 68 69 2F 46 69 74 59 6F 73 68 69 2E 70
61 63 00 00 00 00 00 00 00 00 00 00 00 00 00 00
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
6B 69 72 62 79 2F 46 69 74 4B 69 72 62 79 4B 69
72 62 79 2E 70 61 63 00 00 00 00 00 00 00 00 00
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
66 74 5F 79 6F 73 68 69 2E 72 65 6C 00 00 00 00
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
59 4F 53 48 49 00 00 00 00 00 00 00 00 00 00 00
00 00 00 02 00 00 00 02 00 00 00 00 00 00 00 01
00 00 00 01 00 00 00 01 00 00 00 00 00 00 00 01
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
00 00 00 00 00 00 00 01 00 00 00 00 00 00 00 04
the red numbers say.. kirby/fitkirbykirby.pac
and that file does not exist in brawl disc...and to order brawl game
to load KirbyYoshi hat, it must say..
kirby/FitKirbyYoshi.pac
and the problem with luigi is alike, but it says
irby/FitKirbyLuigi.pac
in the folder name says "irby", instead of "kirby"
this problem can be easily fixed. this issue was because a PhantomWings "bad slip of finger"