@Jerry Tremble, lol that might be a good google search term - didn't think of 'stacking', so will go off and try some more googling!
Thanks for the input. I am glad that someone else has wondered about this as I was kinda thinking I was just being a total noob!
When you use the mirror modifier the UV for the two halves are stacked (and mirrored) in the same location. So somehow blender knows that they are stacked and only renders the AO once. So I was hoping there is a way to tell blender that you want, like 3 or 4 faces mapped (stacked) to the same area on the UV, and only render the AO once instead of 3 or 4 times. This of course gives the ability to have more detail on the model.
I have tried mapping them to same location manually, which is not that difficult (can be time consuming though lol) and seams to create no problems in Game Guru except for light-mapping as you mentioned, however I have to use something like Shader Map to create the AO, but Blender gives a far better AO in my experience.
Now as you can see I have high-jacked your term 'stacked' which for the life of me I did not think of for my description, so I will go for another google hunt now.
Reliquia....
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