Is it possible to create a custom PC face without replacing the originals?
Yes it is possible, read This (
http://www.lucasforums.com/showthread.php?t=149992) tutorial for more info
And FYI, typing
in color is distracting ;)
Ooops, just realized something: This tutorial is for new faces in KOTOR 2. Do the same instructions apply in KOTOR 1?
for the most part the tutorial will work for k1 heads. You may have to Hex edit the MDL file for some heads for K1. However most of them should work the same way as the tutorial for K2.
Is there a tutorial for making new faces for KOTOR 1?
If you're just re-skinning it, then yes, for modelling however, you'll need to use a KotOR 1 model, as using a KotOR 2 one would either not work or if re-compiled properly, it would work, illegally, and thus would not be a suitable topic for this forum.
I want to re-skin and slightly alter a KOTOR 1 model with Gmax.
You can't edit the head model directly yet, however you can re-skin it. Darkkender's tutorial was for using a different model altogether, however you can use that tutorial if you wanted to play as, say, a Twi'lek.
But there must be a way to model in Gmax based on an existing face, recompile it and add it to the game without replacing any of the existing faces?
No, animations are unsupported in the current version of mdlOps (0.5.0).