I'm building models for an independent game and would like to use normal maps. I started by building the low detail meshes first, which are about 4000 tris each, give or take a thousand. I built the low detail meshes in pieces to save on polycount, so when I bake a normal map onto the low poly mesh I get all kinds of errors where the high poly mesh is being projected onto the overlapping faces, no matter what bias I use.
How can I bake normal maps for these meshes? If I have to redo these to get there, what should I look out for in the future? Should I have started with a continuous mesh with all the detail and then deconstructed it to make a low detail mesh?