hmmm don't know if this is what your problem is but I usually have alpha channel problems (with an alpha channel the black isn't counted as 0,0,0 and you have a black box around your unit. I think it happens when you save with a transparent back ground or something..
When I notice I have such a tga file I usually just create a new image of the appropriate size (rgb colors) and ctrl A, crtl C (select all and copy) and then paste it in the new image and the alpha channel is gone. 3 sec work.
No idea if that is really your problem though since I don't really understand it all
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