@BucketOfNuggets This tutorial came to mind. Basically translate the steps to a substance workflow, which should actually be way more efficient than nDo/xnormal as described.
here is the screen shot of the geo. I will try the above steps to see if that works for me. I have to get this finished and start texturing this guy for class.
We learned a lot during our research as well. This article is only the first project of something bigger! We will post the next steps on Polycount too.
It's fine if you get no errors! We have more info on optimal workflow here, along with reasons for each step. http://wiki.polycount.com/wiki/Texture_Baking
It should never be the first step. If it is, they're just throwing them out there without considering the impact on the applicants. Probably not a place you want to work anyway...