Move all the overlapped/mirrored bits one unit away in UV space before you bake the normal map. Only one copy of the forward-facing UVs should remain in the 0-1 UV box at baking time. More here: http://wiki.polycount.net/Normal_Map#UVCoordinates
Artists who worked on gears. Some really good environments in there: [FONT="]Danny Rodriguez - http://www.cgchannel.com/news/viewfeature.jsp?newsid=6969&pageid=0[/FONT] [FONT="]Jay Hawkins - http://www.hawkprey.com/[/FONT] [FONT="]Mikey Spano - http://www.mikeyspano.com/[/FONT] [FONT="]Chris Bartlett -…