So here is some comparisons of tangent vs. object
(Disregard the seams in the middle, I am just testing out one specific half of the body. And I am leaving out the bolts from the high poly in the bake.)
The only way I have been able to get rid of those nasty burnt skinny triangle errors is by adding many "supporting edges" to ease the smoothing. Which jacks the polycount up.
The best way to fix all if this (what I have done in the past) is split my uv's here:
and make those edges hard. Those would save polys and yield perfect bakes. Unfortunately this would give me a nice seam in texture painting and because this in a rounded single piece of plastic, that seam is going to look way out of place. If it was metal or something, that would be easy to cover up and would look realistic since metal pieces have seams when they meet.
Hope this helps anyone having the same issues I was having