Can somone explain to me exactly how to do this please, I would really appreciate it, or just point me to where I can read how to do it, I really need some heads up on this. I don't understand how to save the new info to the npc zip file.

I made a few by opening assets1.pk3 with winace then went to assets1.pk3\ext_da. Copy a premade file across to E:\Program Files\LucasArts\Star Wars Jedi Knight Jedi Academy\GameData\Base\ext_data\\npcs. Then open with notepad and just change around the names and values should all be pretty obvious.

I'am having trouble making kiadi mundai, coleman trebor and zam wesell working though. I used the rodian.npc for zam and kyle for the other two the model names appear to be right but they will not spawn.

Any1 any ideas ?

if you paste what you have in the npc file here I can tell you where you have gone wrong. I've done alot of npc alterations.

I did this but I'm confused how or where to save it.

In the tutorial I wrote about replacing Jaden in the JA skinning forum I talked about editing .npc files. You can have a look there and see if it is any help...