I know I've seen ppl mention this problem before, but as you can see I have a wierd lighting issue of shadows showing up even though there shouldn't be any.
Actually I was talking about the wooden boards. They have a dark gradient. Its fairly visible now, but when I build the lighting as higher quality, the shadows become almost black. I've uploaded a medium lightmass build so you can see it more clearly.
If it helps, here is a wireframe of one of the boards:
I've done some experimenting. If I harden all the edges the effect is gone. Upping the res has little to no effect so it isn't bleeding. It could still be inverted UV's (I'm guessing) so I'm going to try that. But other than that I'm at a loss. The hardened edges work, but doesn't look as good as the softened.
You have the boards smoothed, so this is a clear case of that same smoothing just carrying over a little too heavily in the lighting, not lightmapping or normalmaps - manually adjust the vertex normals of each planar face (ie all faces but the bevels) to align to their faces and you'll get correct lighting. Since you're using Maya, check under Normals > Edit Vertex Normals and make them point perpendicular to their corresponding faces.
EDIT: Like this:
On UDK import you will have make sure to have "Explicit Normals" checked, and probably reimporting the model manually again instead of just right clicking on the existing mesh and reimporting from there, because UDK can be a tricky mistress
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If it helps, here is a wireframe of one of the boards:
Any thoughts?
You could also try subdividing the boards along the middle once or twice.
What does the normalmap for these boards look like?
EDIT: Like this:
On UDK import you will have make sure to have "Explicit Normals" checked, and probably reimporting the model manually again instead of just right clicking on the existing mesh and reimporting from there, because UDK can be a tricky mistress
Edit: That did the trick alright. It looks the way it should now. Thanks a lot!