Do you close your browser before extracting the archive?

By using Google, I found "StudioMDL.exe doesn't exist for Mac and Linux", so you wouldn't be able to compile the model, anyway.

Oh. As I use Windows 7, I don't know, but what's in the linux32 folder?

Well, for Team Fortress 2, it's normally C:\Program Files (x86)\Steam\steamapps\common\Team Fortress 2\bin. For Source FilmMaker, it's normally C:\Program Files (x86)\Steam\steamapps\
common\SourceFilmmaker\game\bin, unless "SourceFilmmaker" has a space in it.

Basically, it's the folder which contains StudioMDL.exe, and is usually found in ..\steamapps\common\Game name\bin. (Garry's Mod doesn't have one, though.)

Basically, yeah, unless you'd go ahead and copy the Blender object as many times as there are flexes, rename them all, and remove all their individual flexes except for one. In which case it'd still be best to just have one VTA.

If "the faces" are "not completely identical", they'd have to be separate Blender objects, in which case they'd export their own separate VTA files (as far as I know), not one big one.

Exactly why would you want that? They would all have the same base shape, anyway, so what'd be wrong with just not using some of the flexes of the VTA?

I said SMD, not QC.

I don't think Team Fortress 2 supports DMX (other than that one player stats file), but it neither supports SMD. StudioMDL, which is used to compile SMDs and DMXes into MDLs, supports DMX, though. But yeah, I have not the slightest clue what the error in Blender could mean. Can you import a different SMD (or DMX), and export it if you make no changes?

1904x1001? That's a pretty odd resolution for a monitor. Either way, nothing there seems to be out of order. Try using DMX instead of SMD.