On a hunch I went to the in-game gallery and that Sim didn't have only the 'remove from my game' option when hovering over him. So I was able to successfully download him into My Library from my Catalog and ultimately into the save file as a Townie.
Thanks for the tip @SweetieWright_84, but I have never used CC in TS4 because all I had was an old toaster of a laptop which is now a brick. However, now that I have a proper gaming desktop, I will definitely be downloading a little now. :)
Thanks to you too @GalacticGal I had already previously created the save file I wanted to use and knew what to do to make him a Townie. I go through most of the steps you mentioned, except, I don't put them on a lot, I just cancel the 'place on lot' or 'move in' and the Sim is automatically put 'not in world' as a Townie in that save file.
I'll probably eventually put a few in houses and use them for mates and/or friends, etc. of the main Sim in this save file. I didn't intend to actually play out their stories though. That's why I put them in as Townies. I just wanted to see them in venues, at work and as walk-bys, etc., to give them a chance to finally 'live' in my game instead of languish in files on my hard drive or in the gallery.
I apologize for the late response to your very thoughtful replies. I posted this thread, went in game for a few minutes, found the solution and then had to immediately leave to take care of my Grandson so I wouldn't be late. I didn't have time to post again until now. Thanks for understanding and...
Happy Simming! <3
