What do the UVs look like in Max? Are they all welded, and all facing forward? What does a regular uv checker grid look like on the lowpoly (with letters and numbers, something like this: http://wiki.polycount.com/wiki/File:Uvrefmap_grid_small.jpg) A couple things to try: Make sure the verts aren't split: Vertex Weld…
Additionally, here are some general notes from looking at the meshes: * Highpoly (for example 'head_high') has some hard edges which will show in the normal map, would shade those soft * If the edges come out too tight, I would exaggerate the bevels of the highpoly some so they hold up when viewed at a distance. Wiki: Edge…