Well I decided the best way to keep my companions armour up to date was to get a full set of modular gear. So I popped off to Nar Shaddaa to get my newest apprentice Ashara some "tastefull" new clothes. After making her build a full set of armouring and mods and put it on her and http://imageshack.us/photo/my-images...012501030.jpg/
She's now a floating head!
Presumably no textures have been drawn for her body/skin so she just becomes invisible. Probably should have previewed it before sticking all those enhancements I bought into it.