If you break the UV on each 90 degree and harden that edge you wont get any seams with enough padding. I didn't go through the entire model on the screenshots I posted.
Is this out of date practice though? I'd also like to know if it is, I tried this 'sync'ed workflow using 1 smoothing group years ago when everything was supposed to be synced up and never got good results for hardsurface bakes going from Painter into Marmo, I think I even did a post about it quite some time ago.
For production we opted to just do the typical break UV island and harden edge at 90 degrees and we got seamless bakes all the way into game engine (Unity). We also ran into the issue with compression, when you make the entire model completely smooth the normal map is working twice as hard to correct the smooth areas resulting in some banding and gnarly stuff happening in game. But I am a bit old school in my ways now
