ok so my prob is, i had to scale a character down, to avoid rebuilding my biped i used the rescale world utility, that was all good, but when i go to load the ENV i saved out it is treating the smaller biped as the large one, is there a way around this, or am i going to have to reskin it???
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Env files save vertex weights if the vertices have been baked/adjusted by hand. For verts that are just 'enveloped' and haven't been adjusted by hand, their vert weight is not saved out (it is, on the target mesh, affected by envelopes again). The bone envelopes are also saved and loaded but this is mostly useless for games. If you are having problems transferring vert weights, it is because your verts are not baked- either bake them, or you can select your verts, give them some weight to a bone, then remove it- that is like hand-adjusting all of them and will remove envelope influence.
Edit:
Disclosure: The following method was tested with 3D Studio Max 9 32bit on Windows XP Professional. Any alterations to this setup does not guarantee the same results and the individual posting may not be stabbed or laughed at under any conditions in regards to the above post.
I'm telling you why it wasn't working and missing verts.