I reworked my Minifigure Mosaic script to deal with the problems with the hands - if I'm honest it's a bit of fudge - the script now watches for part 3820.dat (which are the hands) and applies a 45 degree rotation in the Y axis - the hands are also re-positioned slightly father apart by the script - I still don't know why, so I moved them closer together in the library model - it works (in respect that I don't have to fix all the hands in excel but it still needs some more work). The problem definately lies in the way the rotational matrix is processed. I'll keep digging.
Here's a Batman Minifigure mosiac (I added a tiny bit of disco lighting - well it's Batman!)...
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