As Jeff mentions in the first post here, you have to be aware of that potential for a 4 byte error. If you take the BFD database, and extract a segment to RAW, use PhotoShop to convert to greyscale, and then indexed color, as described in the GWX Terrain Extractor, do not "Save" the data in any other format other that PSD if you might want to edit it further at a later time. Once you go to Save back to RAW for a convert to ZHF, that's where you have to be careful with the "header" data as Jeff points out, else you have an improper file, although it does convert into a ZHF file. That might be why the game is not letting you re-edit a segment... ??
I'll be checking some of the "tiles" we did in FotRSU, and I'll let you know what we find with out stuff. We did a few files and had no apparent issues, but I am not going to be surprised that I don't find a "size error" when attempting to load the files again... which will mean that we have header errors in our files...