Just checked your latest version with the last SCI (4945) and I noticed that Needle's AIM gear selection does not work - all 5 kits are the same and except for the fifth one, they cost the same. Fifth one is more expensive than the rest.

MERC site is a mess, merc potraits and bios change, depending if I'm clicking 'next' or 'previous' when browsing them. I saw Larry's face at least 3 times, with both versions (sober & stoned). There is no Beth at all.

r4945 already containts some DG mercs (from your previous builds I guess) so maybe that's the problem?

And it does not work with saved games. When I load the game after applying your mod, the new mercs are unavaliable and have 0 stats and 0 salary. MERC site is even more messed up.