Is the front of that box sharing the same smoothing groups as the side? It looks like just a smoothing error to me. Split the smoothing groups at 90 degree angles as well as the UVs.
Nope, it's not sharing smoothing groups with the sides. In this picture the separations between smoothing groups are cyan. I split the UVs along the smoothing groups as well. The light map UV is split along the exact same lines as the texture UV.
Really nice! Looking forward to see where you take this! One thing that needs major work is your smoothing groups. Everything looks so round and low poly! You can try to add support edges here and there to make the edges look chamfered. That will also help a lot when you texture this scene. Specular maps look pretty good…
You have a lot of smoothing errors in there. A rule of thumb, if the mesh shades strange in the viewport it will most likely shade wierd with the normalmap applied. Keep in mind that the normalmap is based on the faces of your lowpoly mesh, if the mesh have wierd shading the normalmap will try to counter this (this is…