> so you would have to use an ISO in conjunction with a save file to make a PROPER custom villager?

It is a lot of work, and it would only work in your town, when you view your town.
When visitors came to your town, it would use the builtin model (on their ISO).
See this thread for more discussion: http://game-hackers.com/threads/1678...ation-Requests

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That's the cool part about NPC_Tool, the customized textures are seen by all visitors to your town.