So I created a shocked Arf trooper and it looks great(need to update texture), yet in game, the gray .msh on his helmet is blacked and has no texture also the Kama ingame does not appear yet in mod tool and swbf viewer everything thing is visible and correctly textured? any ideas why it is not showing?

It may seem obvious but did you make sure the .tga file for the new part of the helmet was copied over to the msh folder?
And, is the kama supposed to be cloth or a regular addon?

yea the files are correctly placed in the in the proper file, and it is a regular addon no cloth

have you tried a manual clean??