I'd just smooth the trouble areas and project again. If the lowpoly doesn't match the highpoly, you'll get those results in the first image. You might also want to Geometry > Freeze SubDivisionLevels > select the Zmodeler brush, and alter the lowest subdiv so that you get better projection results
It depends. Highpoly or lowpoly? If it's highpoly you can float it to make things simpler. In the lowpoly there are pros and cons to both. Generally for the highpoly you separate the objects as they are in real-life.
Hey :) so i just finished the Highpoly :) Right now im working on the Lowpoly :) Next update will be the Lowpoly with normal maps baked c&c is very welcome!
seems like your lowpoly is also projecting onto the bake , just select the lowpoly , right click , properties and deselect "cast shadows" that should do it :) nice shottie !