So I was some time afk, but I'm back on it now. It seems the visible edges that were bugging me are seams that were baked into the normal map. I tried around a lot and read all I could find about it but the way to go is to reduce the seams. So now I have a new UV layout and unwrapped the body with almost no seams. The negative side is that I have some stretching now. Also I added some geometry in the belly area, it's smoother in an area which is seen a lot by the player.
like this? If the colours are good I will continue with texture painting some details, eyes, mouth, sandals etc. Don't mind the offset of the quivers, it was made just for clean baking
The fact it doesn't crash is because I don't use the AO ingame. I just bake it together with the colours on the diffuse. So I feed the AO that I baked into the nodes of the materials in blender. That's how I understood the instructions. I could also add a AO map in the actor if that's better.
also let me know what you think of the uv layout now:) @Stan` @wowgetoffyourcellphone
Normal map baking stays a problem though, even when baking with a cage. Only solution I see is editing by hand afterwards, similar how this dude did it: