That's an idea. I'll try that next and then I'm off to bed.
I'm trying to gleem as much info as I can from this experiment to figure out how the character file structures work. I went into the necropolis with the previous hacks installed. I could load the models for all the dlc characters just fine. Also when I selected Shang, Shang's model showed up, not noob's. So you would think that the startup mods only effect the player select from that, but if I try to view shang's alternate bio the game crashes... probably because classic noob doesn't have an alt costume.
So whatever that tells us (I'm not exactly sure) it's probably related to why we can't add extra costumes.