Hello again,
3drotate has been modified to store the transformation in the output dataset's header and SUMA has been modified to use them.
In other confusing words, if you align your surface volume 'SurfVol' to your experiment's anatomical volume 'ExpVol' using 3drotate, the output dataset ('SurfVol_Alnd_Exp') contains the transform necessary to bring the surface models into alignment with your experiment's data.
In yet more confusing words, the changes makes what Kai was trying to do via 'Nudge Dataset' and 3drotate work.
The reason 3dvolreg was failing is the large difference in coverage between the surface volume (SurfVol) and the experiment's anatomical volume (ExpVol). In such cases, manual alignment is the way to go.
Binaries with fixes will be available sometime this evening.
cheers,
-ziad