Hi emdee,
This black silhouette is the classic result when you try to apply polypaint to a texture map from a polymesh that doesn’t have proper UV mapping.
Try this with your polypainted model in edit mode:
Under TOOL:Texture, click on AUV. (you will have to set TOOL:Geometry:SDiv slider to 1, first). ZBrush will apply UV mapping to your model.
Now, be sure your texture map is selected and simply click the PolyPainting buttons in this order:
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Click SaveUV button - when it asks if you “Initialize PolyMesh with Texture Map colors?” ANSWER NO…
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Click HideMap button and you should see your polypainting on the polymesh. If you didn’t save your model with the polypainting intact, apply new polypainting until you are satisfied…
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Click ShowMap button and you should see the original texture map reloaded.
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Click PolyPaint to TexMap button and your polypainting will be transferred to the texture map.
Sven