Just tried the obvious test, my prefab in an empty scene...
Everything was fine, I could resize the character and it stayed.
So I got a clue now, it was the spawning, so I spawned the character into the scene, and sure enough it was 1.5.
Scratching my head I performed many new tests.
FINALLY I realised that this FPS character Controller has some additional functions (this is why Im using it after all) It can climb ladders, and crouch, and crawl)
Of course I figured out that 1.5 was the height it goes to if you hit the C (crouch) key..
BUT STILL WHY??
More tests, It seems to like to trigger this functionality when it hits "someone elses code" (the best way I can put it)
For example, in one of my scenes, it will shrink to 1.5 EVERYTIME it goes thru a door! I have of course got some code on the door (half is PlayMaker, for triggering a door sound) and half is UScript (your competitor.. promise I didnt buy it, Im a PLAYMAKER guy... this tint bit of code came with the asset package, and Im using it until its no use to me anymore, maybe thats now..) but I still cant figure out WHY!!!
Anyway, its not specifically a PlayMaker issue, Im happy to share my scene (TO honest, non stealing types only) if someone is willing to take a look, but... its 250 mb
Mark