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1024*1024 is a multiple of 256*256.
What does the mesh look like in Milkshape? You will need to make the morphs, yes, but it's better to fix the first problem first, since otherwise your morphs will also suffer from it.
It looks like you're using the EA texture for the hair you've cloned from - perhaps the "gap" is actually part of the texture alpha? Have you tried turning the whole alpha white to see if the gap still appears? What about if you look at the hair in wireframe view - does the mesh meet up at the back?
What I lack in decorum, I make up for with an absence of tact.