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Ok, so we don't seem to be following you...
Is this, perhaps, what happened?
You started a game, and made that sim in CAS.
You went into town with that sim as an individual household, so that you could place him individually later.
You went back into CAS to make a new household including that sim. That sim was no longer visible in CAS to create a household with.
If that is the case, the sim was never saved to the CAS sim bin. Put the sim onto a lot (any lot, in any world) and find a mirror. Click the mirror and Change Appearance. (Or use Edit in CAS from Master Controller, and skip the mirror.)
Now you can find an option on the icon of the sim's face to "save sim to bin. " That is what you want to use if you want to keep him available to add to a household in CAS.
Or you can just make the rest of the household, add it to the world, then use Edit Town to merge him with the household. You may need to fiddle with Master Controller to repair family ties, though.
Edit: For "CAS" read "CAH." Most of us got so used to it being called Create-A-Sim that we're stuck. It's like my great-aunt who used to give directions like "it's 5 miles past the Grange hall that burned down 20 years ago."
I am Ghost. My husband is sidneydoj. I post, he downloads, and I wanted to keep my post count.
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