I played with calculator bulit-in in xnormal but couldn't fix this. Didn't try the exploding, sounds like a good idea. And sorry for noobish question but what is cage?
So, a cage is a copy of the lowpoly mesh (but with soft normals) that takes the place of ray projections. Generally, it's a much more flexible system, and gives control to the user in a million small and useful ways.
Basically, duplicate the low, soften the normals on the duplicate, and expand (using the transform component tool) until it's covering up the highpoly entirely. Then you load that into xNormal as a cage, and it bakes using that instead of rays. There's plenty on polycount, and google, about it if you search.
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I'd suggest using a cage. Are you exploding the meshes before baking? (moving them away from one another, so there's no interference)
Basically, duplicate the low, soften the normals on the duplicate, and expand (using the transform component tool) until it's covering up the highpoly entirely.
Then you load that into xNormal as a cage, and it bakes using that instead of rays. There's plenty on polycount, and google, about it if you search.
You still need to explode the meshes though.