From: Wire
I find 3d modeling extremely fun everyone defiantly should give it a go, especially if you're in college because of the three year trail on 3ds max. The current status of this mod is in the progress of retop into low poly so i can begin baking(will keep updates posted if liked as well). If anyone likes i can post some other models I've worked on such as tarantula turret and such. These models are all based from the warhammer 40k universe.
You shouldn't be using Nurms with smoothing separation to do your highpoly model. Baking a normal map for your low poly will be next to useless in this case as you gain no edges from the highpoly. You're wireframe looks solid so this shouldn't be too much extra work… Use a TurboSmooth modifier and add a bunch of edge loops to support your geometry for the highpoly. Remember to keep your edges loose. To the eye it might seem too loose but to the baking engine it'll be just right.
Also, IIRC UT2K4 doesn't support anything except a diffuse and colored specular so why bother baking anything. Just paint your normal in NDO and overlay the details onto your diffuse.