The lastest trouble is finding the right bones in a complex model. Is there anyway to reduce the size of the generated bones any more than I can already? What is the initial size (10 in the generation pop-up) determined by?
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ptbone.fLength = diag:Mag()/GE_front3Drig3_2.ptscale
rxbone.fLength = diag:Mag()/GE_front3Drig3_2.ptscale
Lines 282 & 291 seem to be the scale in the 3Drig front 3.2 script. Bone length equals point scale? Is that what it says? How does it determine point scale?
Perhaps if I change the 'recurring' value of ptscale?

In ge_front_3Drig3.2.lua script look for this section:
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function GE_front3Drig3_2Dialog:OnValidate()
local b = true
if (not self:Validate(self.ptscale, 5, 30)) then -- those values (5, 30) can be customized
b = false
end
return b
end
It checks if the scale to the pt bone (and to the Rx bone) would be accepted or not. Maximum and minimum values are [5,30]. You can change them for your convenience.
Notice that the default value is set once you run the scrip after start AS. It is 10 and comes from this line:
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GE_front3Drig3_2.ptscale = 10 -- dividing scale for the pt, Rx and Ry bones
but once you change it, it is kept until you leave AS and run it again. You can also alter that number too.
Understanding the lines:
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ptbone.fLength = diag:Mag()/GE_front3Drig3_2.ptscale
and
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rxbone.fLength = diag:Mag()/GE_front3Drig3_2.ptscale
it means that the resulting bone length will be the result of dividing the diagonal of the selected points to 3D rig by the ptscale value. So higher ptscale value decreases final bone length. Also if for some reason the diagonal is is a null vector [0.0, 0.0] then the diagonal is set to [0.5, 0]. See this code:
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mesh:SelectedBounds(min,max)
diag = max - min
if (diag:Mag() == 0) then diag.x = 0.5 end

Unfortunately there is not GUI interface for the 3Drig side script. The ptscale value is always set to 10. You can change it modifying this line:
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-- ***************************************************
-- Magnitude of the .pt bone in relation to the diagonal
-- of the selected points boundary.
-- a value of ptscale = 10 is sane 1/10 of the diagonal
-- beyond 30 could be insane.
-- ***************************************************
ptscale = 10
20 would be a good value.
Good luck
-G