Show us some complete wireframes of the shield? 2k textures are definitely too high (unless you just authored at that so the client can downsize as they see fit?) and also the polycount seems much too high. From that partial wireframe it looks like you've got a lot of waste, and what's up with the UV's for it? Depending on…
Deathstick: Thanks, I've messed around with projection in mudbox before. I went through Magdelina Dalena's Napolean tutorial and she used a similar approach just using zbrush instead. Looked great, really quick.. just didn't have a 3dsk subscription so couldn't try it out myself. I'll google a faces somewhere though and…