It has been a while since your first post and it still doesn't seem you have implemented what these guys were talking about. You were asking about the UVs and I still think you could maximize texture space with what you have.
He is pretty symmetrical so cut everything in half. Straighten out the curved pieces and repack. Notice the negative space. And scale up to have a higher quality texture, or cut the texture size and impress with what low resolution you can texture at.
Yes you might have to retexture some things but he is pretty much just solid colors so I don't feel it would take you much time to redo it...
Aside from your UVs... you could get some reflections on the metal. Define materials a little more. Look at what gloss maps do and how you can use them to make his spandex look like spandex and the metal to look like metal and the skin to look more like skin.