Figured it out!
When you use the upload system in the badge system to upload a badge... the system (or SMF) renames the file. I uploaded kenbadge.png but the system renamed the file 4fe34166e66c4.png... when I changed the name of KENBADGE.png to 4fe34166e66c4.png... it worked... clicking on the badge loads up the larger one.
Forgot I did the reneaming for security reasons