If only you asked this like 4-5 years ago, I would know for sure what the problem was. Though I've never played BoS, but from what you're describing, it sounds like some NPC files have been edited that have duplicated names in other modules. That's the thing with the KOTOR games, especially the 2nd one. Every module has a list of NPC names whereas an NPC will have a name that doesn't necessarily reflect the character that you come across in the game.
The point is from what you're describing, an NPC was edited in a particular module that is used in another module as well like in your case the Star Forge and it carries features that are designed for the module that it was edited for and it screws up the module that had the duplicate NPC name because when you put that in the override folder, it will use the same features for the same NPC names for all the modules that has that particular name.
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