Need Help, yet again

I need help yet again..

I generally like to answer more questions than i ask, but unfortunately i'm having a string of rather bad luck with modding.

My problem started when i had the great idea of mapping each light on a lightbar to a different place on a texture, allowing you to change the color of any light on the bar.

So i created a 1024x1024 image of all the lights in photoshop, and went about mapping each light to it's respective place on the texture.

When i loaded the car in game, it worked!

I replaced the texture with a new one, and i had new colors!

When i changed it back, however, things started to go horribly wrong.

Here's screenshots of what i encountered:

Noose:

Here's police, using the EXACT same model, renamed:

After going back through to models to noose, this is what i came across!

Unfortunately, the "complete" version shows up about once every 40 cycles. (yes, i counted)

I'm honestly stumped as to what to do. I tried replacing the 1024x1024 texture with a 512x512 one, but that didn't fix anything! I'm considering remapping the whole thing, perhaps zmodeler is scaling the 512x512 up? I'm not sure, but it's worth a shot..

I replaced the .wtd a few times, and it would occasionally fix the issue. However, loading the game up the next time it was broken again.

Any help, as usual, is greatly appreciated.

Thanks!