Imo the lightmass solver just sucks at this, you'll get best results if you snap the UV verticies on a grid that shares the resolution with your lightmap.
I agree-- give it a more unique silhouette, if you can spare the tris. Right now it's barely a sliver on my screen, I'd be concerned that it wouldn't be visible at all in-game.
Looks good, but what is going on in the adam's apple area? it looks like you have a tiny sliver of a face :) Get rid of those (unless it was just something weird going on in the screenshot).
I'd take the straight one - gives better protection to your hands. :) Both of em look great. What I'd change is the blade texture: There's an odd polishing line where the blade is attached to the handle, right at the edge where it meets the Cross-guard - swords are polished when it's still disassembled- this wouln't…
What a pain None of the tile generators or sampler can do this and I couldn't come up with a good solver idea either so it was faster to do it by hand.
Blade is looking sharp. A little unsure about the green sliver, might be a little too subtle for a character Riki's size. Looking forward to seeing it wrapped up.
I second Aphrodite X, you can go completely bananas with a cyborg on their last legs (no pun intended), completely shattered, mustering the final slivers of energy left for one last attack...