Check your Projection Cage and padding. You also might want to have a look at this http://wiki.polycount.com/NormalMap?highlight=%28%5CbCategoryTexturing%5Cb%29#Sloped_Extrusions
hahahaaaaa I still play that game ^. [ame=" https://www.youtube.com/watch?v=VRO9mVFt7Hw"]Kid Chameleon Speedrun in 28:55.80 by peaches_ - YouTube[/ame]
http://wiki.polycount.com/PhotoshopTools?highlight=%28%5CbCategoryTools%5Cb%29#Export_Tools a whole lot of them on the wiki. I personally like d1vSave, dunno why :)
Here is a video about swords, it explains the importance of the sword's concussion power at 28:37 and gives an example on a helmet. Check it out : http://youtu.be/1SijLXKmlsw