Hi Alwin,
As I told Bobby the same thing just happened to me as well, good timing I suppose, anyways both my wife and I tried what you said Alwin and found that it was easier to do it in Default Female & Default Male mode. (basic SL avatars...ughhhh..lol) and it worked well.
For me it was a mesh hair that had created the problem, we are not sure with my wife but it looked like it had something to do with her eyebrows, but either way we made them transparent so for all intents and purposes it worked.
I would really like to thank Alwin & Bobbie for your advice and ideas as they were really appreciated.
A big thank you for all who replied it was great to have so much input into our problem.
Rheaven Resident