This was done in Blender, by the way.

There should also be a file under templates called HatAndFaceItemBoundingBox.obj, This will show you as far/big as you can make an item; going outside of it will make it so you can't import it over.

I'm having this same problem right now. I've used the templates. The mesh is certainly not bigger than the bounding box, it's nowhere near the poly limit & the texture is about 3/4 of the maximum size. I can't figure out why it's doing this.

Same LightninLew -- I mean, I dunno, maybe the exported file is including more data than I understand -- but the "size" of my object is BY NO MEANS bigger than that box. I can't figure it out.

I've tried quite a few things, and I still can't work it out. I've tried making them so small that they wouldn't be visible in game and still get this message. I've made sure I'm only exporting my model (export selected with isolated object), I've cleared the scene, I've made sure the units of measurement are consistent with the OBJ templates. My pivot point is centred on the object. I'm all out of ideas.

Actually I just had another idea whilst typing this. It's a long shot but I'll come back and let you know if it worked.

I'm using 3DS Max by the way, so this isn't just a problem with you using Blender.

Cool. Let me know if you sort out anything LightninLew. I don't have anything as advanced as 3DS Max but maybe what you find will sort it out even Blender-wise.

Well, that didn't work either. This seems like something so simple, I don't know why I can't work it out.

I'm going to import one of the templates and my model into a Unity scene to see if there's a size difference, or something like that.

Has anyone figured this out yet? I didn't have time to start messing around with it until now & I've hit a dead end.
I imported them into Unity & there was a huge difference in size. But the opposite of what I expected. The template is about 50x the size of my model. This is not how it shows up when I import it into 3DS.
The model is also imported with a rotation of -90 degrees, but the template is not. I thought that this could be because Unity uses Z as the depth whereas 3DS uses it as the vertical axis. But if that was the case, why does the template have the same orientation in both?

I'm out of ideas on how to fix this.

For *me* it turned out to be my .TGA resolution, LightninLew. Let me know though for you.

(For the record, I still haven't managed to get it any textures done in other programs to work -- I have to manually supply them every time -- all two times I've done anything, at least. Heh).

Damn. That's a bit annoying. Why would a problem with the texture return an error about the mesh? All this time trying to figure it out is totally wasted if the error message isn't accurate. My problem could be caused by anything. No point trying to fix it any more then really.

My texture is 240 x 207. Well within the limits. What units did you use for your model? I've tried all of them, so I don't think that's my problem, but I wonder if it does matter.