Yeah you're right, I did notice it got a little too 'noisy', I'm not sure yet however because I won't be tiling it more than 2 times max. (it's used for a relatively small room).
As far as the grill goes, it does indeed look a little weird, I'll adjust the cage/model a bit and check the results.
I don't see any baking mistakes though, the curve itself is already fairly high poly, the 'mistake' could only be solved by adding more geo in that area, I may or may not do that depending on how it turns out with the textures.
I didn't make the panels as geometry but rather as normal map detail because it would have looked uglier (at least in the Unreal Engine 3) but since the HPL2 doesn't use baked lightmaps I guess I can give it a try and make it geometry instead.
Thanks.
edit:
Alright I've made the modifications, I think it's ready for texturing now. Even if it looks too 'repetitive', remember that I will only tile it twice at most (the room I'm using it for is pretty small)