@m4dcow I'll explode the mesh and check out SD5 then! Awesome. Even if I model as a single piece, I'll still have to explode the mesh because of the handles on the back. (didn't post it earlier) Will let you guys know how it turns out later tonight :)
So if I had a more complex model, i'd bake them separately and then combine the normal/vertex maps in photoshop? Guess there's no other choice because of the way it's calculated. I'm assuming AOcc should still be baked together though, right? But in this case just start from scratch and make the wooden planks / center…