@eithman The normal map baking can sometime be a headache. Keep tweaking the Ray Distance parameters to even lower values, or try using the Cage option ( a good description on how to use it is available on the Gun modelling course I think).
Also, how do you control the details quality ? Directly on the baked map or using a shader ? I personnaly recommend using a diffuse shader with the said normal map (don’t forget to switch to Non-Color Data!)
