OK, first off your steps are wrong. When you press the AUVTiles or GUVTiles button, ZBrush calculates the mapping based on the current texture. If no texture is assigned, then it calculates based on a 1024x1024 map. So with the steps you outlined, your mapping is based on a 1024 map even though you’re ultimately creating a 4096 map.
Why is this a problem? Well think about it:
With AUVTiles, each polygon of your model gets one square on the texture. With a 103,000 polygon model, that means your texture map is broken down into 321 squares by 321 squares. So if the texture is calculated based on 1024 across then each square can be a maximum of 3 pixels across! But it gets worse: There’s a space of 4 pixels between each square. In short, with a model of 103,000 polygons pretty much the entire texture space in a 1K map is taken up by border and there’s really nothing left over for actual texture. The results are better with GUVTiles, but it’s still not going to be great. Mileage varies depending on the model’s topology.
Now with a 4K map you’re a little better off. You at least get 8x8 pixels per polygon (after compensating for the borders between them). But you’re only going to see this if you calculate the mapping for a 4096 map. If the mapping is calculated for a 1024 map (which is what you did), then all that really happens is the borders get made thicker without providing any appreciable improvement in available texture space. The borders are getting magnified along with everything else.
Here’s what you need to do:
- Go to level 1
- Create a 4096x4096 blank texture
- Press AUVTiles or GUVTiles
- Go back to the highest level
- Transfer the color to the texture
By assigning the blank texture first, you tell ZBrush to calculate the map based on 4096x4096 instead of the default 1024x1024. This then gives you much more texture space.
I did try to point you in that direction with my first post:
Given the number of polys in your low level mesh, you’ll definitely get the best results from GUVTiles since that has fewer borders. However, I’d still recommend trying to reduce your poly count at level 1. You can possibly do this by using Tool>Geometry>Reconstruct Subdiv. Or you could use retopology. However you do it, the fewer the polygons there are at level 1 the less of your texture gets wasted on borders between UV’s.