I brought this up in chat but none of us could figure out why it was happening, so I decided to try here for a broader perspective.
I have the object unwrapped, albeit it poorly. Lights are set up, brought into a fresh scene, everything. For some reason one side of my gun is baked fine, while the other is not accounted for in the normals, leaving a giant black space.
So far we've tried cranking up the cage, resetting the xform, bringing it into a new scene, brighter lights, dimmer lights, shadows on, shadows off, and turning off using the cage and just scaling up the offset. None of this seems to be making it render that side.
http://img371.imageshack.us/img371/7984/riflenormalqi8.jpg
for reference. Basically the top left corner should have an identicle side of the gun, but is certainly lacking. I appreciate any help offered.
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On second thought I think it might be a MentalRay issue, does it still do it if you render using scanline?