[UV Mapping and texture size]

Yep! Not only Dilation there are some nice ones for generating and editing normals. 

[Sharing pics of new mesh work]

Kinda rough at the moment but doing some workflow tests with some mecha like armor. Will give a shot at rigging it when I have a chance.  

[UV Mapping and texture size]

So this is a common issue with games using mip maps. 

My personal recommendation when trying to solve combat this is to install the photoshop filters that come with a popular texture baking application called xNormal. http://www.xnormal.net/

When you do the installation you don't actually need to install xNormal itself (I use it alot though ) and can just install the photoshop filters.  The filter "Dilation" basically takes the pixels on the edges of your UV islands, stretches, and blurs them off the sides by however many pixels you set it to. Provided your textures are their own layer and seperated from the background. This should combat the wierd edge seam issues.