Oh, another little tip.. if you see a tiny bit of pokethrough after the collision detection pops it out do a spot render to see if it's actually poking through... since the viewport usually only shows 1x sub-d if you render him with the HD morphs which are 3x you may not have the pokethrough when it's actually rendered.
I've worked on this for hours, and I cannot get it to work. It looks fine in the viewport but renders with poke through. I'm using pure Oliver (no other morphs mixed in) with HD. Can you give me some specific values to set for the negative !ExpandAll, Smoothing Iterations, Collision Iterations and Smoothing Type? I just can't find a combination that works. Thanks.