1. Start with photo headshot, oriented properly.
2. Launch UPaint, open "fireman.upp" basic model
3. Click "Face Projection" button
4. Click "Load Face" and choose your photo
5. Resize/stretch as needed to fit model (rotate model to check sides, ear/eye areas, etc.)
6. When happy, hit "OK"
7. Click in head viewport, then click big square button from set of three viewport buttons above (to make head fill screen)
8. Zoom image so it's as big as possible but still fits on screen
9. Hit "Print Scrn" key on keyboard (copy screenshot to clipboard)
10. Open Photoshop, make new doc, paste clipboard
11. Crop the image to just the tan square with the UV map on it
12. Open "/fireman/firefacetemplate.psd"
13. Bring new pasted UV map to the front of the screen and drag that layer into the template doc with the shift key held down. Only the face part of your new UV map should appear through a "hole" in the template, with the regular fireman stuff around it.
14. There will be some tweaking you'll have to do to make it look right. Probably some nastiness around the right ear.
15. When finished adjusting, save it as a .bmp -- make sure your new face smear layer is below the layer with a hole in it.
16. Go back to UPaint, click on the "head" viewport
17. Go to File, select Import Texture and select the .bmp file you just created
18. Then save as "fireman-joeblow.upt" or whatever

If you want to see it in the game, just send the face texture to Eric; the texture is all we need, Megan already sent him all the other files.