Yeah I have sussed the emit maps in blender, I got the whole process sorted now it should be cake from here, the main thing was learning the workflow and getting it banked into long term memory so I can repeat without the fuss, the way the file is setup, materials, uv's etc it really matters when it comes to baking.
I have not done much on this project the last week this flu been knocking me out (was bound to happen the time I spend on trains!) but I think the worst is behind me now and I have told work to not expect to see me till after xmas as I still feel like dirt but while curled up on the sofa I was playing around in blender with junk files just learning a thing or two about the process (point and click stuff with the laptop hooked into my new black friday TV

, still don't feel up to coding so I will refine my models with what I have learned
The problem would still stand with PS anyway, I am baking geometry data from a high poly model to a low poly, maybe Substance 3D is more suited for this task but PS would be no better than GIMP or Paint.NET, maybe that's why the 3D functionally is being shipped to Substance, I have found that Paint.NET can make a decent Normal from a heightmap but if the hightmap is wrong you got no chance with the Normal, in my experiments anyway!
anyhou, I think I'm due some more Beechams and some shuteye!