I have been making a cable reel thing.on the highpoly I extended some of the polygons to give the impression of seperate planks of wood making up the structure.
the looks really good on the low poly bake with lots of little dark areas on the AO which is great for dust etc.
however on the main spool, the hp version I extended outwards the polys outwards and obviously thats affected the occulsion bake on the perpendictular polygon, currently Im just going to paint over the area with poor shading so it looks the correct colour but how can bake these things differently to avoid this? how about extending the hp faces inwards below the lp?
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Hope this video helps to understands it (@ 09:55):
http://www.youtube.com/watch?v=ePnLTuzRAbg&t=9m57s