the issue comes from the mental ray implementation that multithread on a per object basis (there's a tech detail explanation about that on the maya station blog). Sadly it's not always practical to cut your bake across multiple objects. you'll get much much faster results with x-normal.
Simple; it's just the smoothing groups. That object doesn't have any (hard edges), and the render to texture tries do its best... but normal map doesn't do magic. There's no way to smooth a 90º angle. Try smoothing the whole object, but you should definitely chamfer the edges.
viewport 2.0 wont speed the actually bake up, just helps with viewport lag and stuff if your working with millions of polys in viewport. As far as baking, just make sure you deleted history on all objects in the bake, the more history a object has the slower the bake.
um... Rage uses Id Teck 5... not UDK. Just fyi, all the environments of the game use the same texel density. Thats why smaller objects seems to have blurry textures wheras the larger objects (like cliff faces) seem so sharply detailed.
I've seen this before but I'm not sure what causes it. It looks crazy like that, but just fine in smooth preview. Usually when this happens to me Maya is about to crash. I believe I solved it by deleting history and combining the object with some other object like a cube.
what i would do is, save a copy of the scene, and in this copy, attach all the objects and make a new UV-map on map channel 2, then add whatever lighting you want and bake that down with render to texture. Then split the objects back up if necessary. And save again.
with the top pictures of the gun 'snapped' ready to reload, did you make that as two separate objects so then you only had to select and rotate the chamber part? otherwise, if it was just one object how did you rotate only one part of the gun? thanks for the help :)
The only way I've seen it work flawlessly is to build a multi sub-object material and name them appropriately before exporting. Build the multi sub from scratch. Chances are you've merged and detached objects and the multi sub is probably containing errors from all that merging.
How should I group objects together? For example: I want to have the doors be able to swing open, should I make each door its own object with its own texture set or have them all in the same one?
Would ObjectWorldPosition work better? The last time I used Transform World Position, it did not discriminate object space, so the parameters only worked at a given world height, rather than applying a up-vector transform on a per-object basis.