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Hi dropshadow79,
First off, do all the avatars use the exact same skeleton, with the exact same scaling and exact same base pose? Basically, did you make the mesh match the skeleton, or did you make the skeleton match the mesh?
What you describe sounds a lot like what happens when a mesh is exported onto the wrong skeleton, so most likley the skeletons differ from eachother in some way, or you are aren't exporting the meshes from the same base pose. Cal3d is painfully picky when it comes to skeletons.
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