Loop cut bug
There seems to be a bug in Blender 2.49b which affects the use of loop cuts for sculptie modelling. If you use loop cuts, you need to select all points on the UV Layout, enable Snap to Pixels and grab and click without moving to force an update. The bake will work correctly after that.
The symptoms of this are inaccurate bakes. I'm not sure how many versions of Blender have had this bug. I tend to do the snap anyway if I've done any mesh editing that affects the UV layout. Thanks go to Manny for bringing this issue to my attention.
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loop cut bug
Thank you too for pointing out that quick solution, I tried it in my tests and worked sweetly, even in the final version of the chair, it smoothes properly the way the seam cross, which wasn't so clean with my solution.
Fixed in 0.9.30
After a long day pouring over Blender source code I gave up trying to fix it there and instead coded a workaround into Primstar. 0.9.30 no longer needs you to snap to pixels to avoid this problem.
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