Hi, I'm currently having similar problems with multiple avatars that are used as Scripted Agents or Bot in SL.
The bots are registered with Corrade in SL.
If I am now online with the current SL Viewer or the Firestorm Viewer > Version 6.4.5 I see my Bot which is registered with Corrade as a cloud.
If I am logged in with a viewer of Firestorm under version 6.4.5 I see the Corrade Bot quite normally with his avatar and not as a cloud.
So the problem is that you can't see any Corrade Bots if you use a newer viewer.
I dont think its a problem with unsaved Outfits or a missing Shape etc.
The Problem is there since a few days and nothing are changed on the Bots itself.
If i switch to older Viewer i see the Bots normal, if i using a newer Viewer v6.4.5 and up the Bots are Clouds for me.