Hi Rafhalzer, I will run one of the un-modified characters through this and see what happens.
Reloaded will load up and run characters over the limit sometimes with no problems, sometimes it really isn't having any of it, depends I think on the rig.
The wings on these characters have an additional set of bones, these are not separate from the biped but are 'extras'. Losing toes and finger bones helped with getting it all down to 59 bones, the original rig was around 84 bones.
In addition to this I have found that Reloaded does treat nubs as helpers and they are not added to the bone count as long as they are hidden on export.
The only problem I foresee with disabling bones and reattaching verts to the parent is, in the case of the wings for these characters, it may mean a serious loss of deformation with these not 'folding' etc as they should. I will run it through and see how it turns out
In my own case this is now a non issue and I will simply create my rigs to be Reloaded compatible but if helps you create a converter for others to get character models into their games then I will help as I can.
If it would help you further with this I would be happy to send you a character to test with
A funny thing happened on the way to the forum...