It seems like this command (e_ScreenShotMinSlices) adjusts the overlapping images. I brought it down to 1, increased it to 8 but the images still come out with errors.
There's no trial and error. You just place your uvs in the uv editor with the map showing in both the uv window and the 3d viewport. It's the same workflow.
You can use a cage to fix many of these errors. The AO requires some tweaking, this might help... http://www.donaldphan.com/tutorials/xnormal/xnormal_occ.html