units and scale issues with Face robot and gear rigs..

[t4d]

I understand the .. open unit system of softimage but sometimes it a PAIN !!

OK rigged afew heads in face robot attaching them to gear body rigs.. scale up the body is distorts,. scale down the face it distorts

so thinking i should check the scale that the face robot templates are ... there are at different sizes too ?!?!

OK so what is the solution ? I created my bodies to a cube so all were the same scale to fit into scenes
but my heads are different sizes ( around 20% range of each other )

do i have to re-rig all the heads or is there a better solution ?