/3/ - 3DCG

>>637556
>>637557

Can't quite see what the problem is, so this may not solve your problem but it's something worth baring in mind anyhow:

UV islands need to be taken into consideration with smoothing groups when it comes to baking, otherwise your bake will suck.

If you have an object with two smoothing groups (eg. a trapezoid where the top is SG1, and all the sides are SG2: pic related) you MUST break the UVs on for the different SGs.
So, the cap has to be a completely separate UV island from the sides or you will have a horrible edge in your normal map.

Also - your UV islands on the bigger chunks look *very* close to each other; they may be bleeding into each other. Pack them with a little more padding.