Well I have my ATI control panel settings at default, which I don't change unless I'm taking some "beauty screenshots" because leaving antialiasing on globally really messes up other programs. So no, nothing special on the ATI settings.
Now when importing the biped into max, the only non-default setting I use is shown below. Strangely, unchecking this setting places the bipeds feet squarely on the origin contrary to what you might think. FPSC uses physics to make the feet find the floor, but I found out from one of Lee's builds that this isn't always true, so using these settings will assure that the feet don't sink throught the floor no matter what.
Strange, opening up the "select by name" I saw the extra firespot right away. Also, when I imported the character it looked like this:
All the stock characters and my own characters import the .X file laying flat on their back facing upwards. Any idea why this character uses this orientation?
Opening up schematic view I see this, the firespot that is linked to the hand is the one in the wrong place, near the waist. The other one in the upper left hand corner of schematic view isn't parented to anything, but is right where it should be on the model. Which makes sense because that huge triangle moves with the model.
What I think happened is that the biped was somehow imported twice along the way, and one of the firespots didn't get deleted, not unreasonable since it's practically invisible. Either that or maybe it got shift-cloned, but that doesn't really make sense because it would have a different name then.
Did you find your max source?
Butters uses Maya, so I don't think his is a firespot issue. But I DO think it's a matter of him not freezing transformations, which is the Maya equivalent of reset x-forms in Max. Large or out of control polys are a telltale sign of not resetting tranforms.