This post chronicles my attempt at importing a new player model into the game, as well as the end result. Hopefully someone can tell me what I'm doing wrong. Thanks in advance for those who look!
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1) Aquire model
Meet Boxman. Boxman was made by Sniperjack for this very purpose. Boxman has been converted to an .sm file and then imported into max, which you see below

2) Import and pose .ske
Next step I imported USSoldier.ske from animations.rfa. Using only the rotate and move commands, I posed the skeleton to more or less fit Boxman. It wasn't a perfect fit by any means, but I don't care since this is only a test run.

3) Weight vertices
I made a skin modifier, added the bones from the skeleton, and used the weight table and weighted every vertex to nearby bones. This is easily the longest step (Especially since Boxman went from 80 to 200 vertices while being converted to .sm).

At this point the skin modifier works pretty well, I think. Boxman can dance!

4) Export
Now, I select the mesh and go Battlefiel Tools > Skeleton and skin > Export .skn. I save it as Boxman.skn. I put Boxman.skn in my animations.rfa file and boxman.sm/.rs in my standardmesh.rfa file. I now need to tell the game to actually use these.
5) Code
I want to make boxman appear as the body of british soldiers. So I open up Objects.con and go to soldiers/BritishSoldier/Geometries.con and find:
GeometryTemplate.create AnimatedMesh Soldier/3PBritBody
GeometryTemplate.setSkin animations/BritBody.skn
GeometryTemplate.file BritBody
GeometryTemplate.hasDynamicShadow 1
GeometryTemplate.setLodRange 0 0 1 30 2 80
GeometryTemplate.setLodRange 3 150 4 210 5 230
GeometryTemplate.setLodPercent 0 1.0
GeometryTemplate.setLodPercent 1 0.7
GeometryTemplate.setLodPercent 2 0.3
GeometryTemplate.setLodPercent 3 0.2
GeometryTemplate.setLodPercent 4 0.1
GeometryTemplate.setLodPercent 5 0.05
I change the second two lines to:
GeometryTemplate.setSkin animations/Boxman.skn
GeometryTemplate.file Boxman
6) Try it out in-game
Load El Alamein and:


Oh yes. I like spikes.
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So, what did I do wrong? I have a working skin modifier in max, so I'm guessing the error is later, but I could be wrong.
I've tried and retried this in various different mods, but the result is pretty much the same. Sometimes I don't get the "no vertices skinned" error, and sometimes the "spikes" actually move when it tries to make an animation, but it is never the right shape.