I did into some major issues when baking the normal map out in Maya, due to problems within the model. The sides of the cannon were too close to the barrel and this caused issues with the search envelope, which led to some unsightly errors once the normal map was baked out. As it turns out, one of the arms of the model was accidentally moved somewhere along the line, and this misalignment also caused errors on the normal map. After reworking the model, I was able to correct most of the issues. Lesson learned for next time! Here's a look at the low resolution cannon with only the normal map applied:
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And here are the final maps that were baked out. The texture map was painted in Mudbox, with some touch up work done afterwards in Photoshop.
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