ok i sat down with the 2.57 version and with 2.56 and have one common result    smart unwrap is trash

after using standard unwrap versus smart unwrap 1 thing is clear    smart unwrap unwraps in a manner best fitting the mesh data and not the mesh itsself

use the old regular unwrap and apply the texts and try again because the smart-unwrap actualy flips certian normals and confuses the render

i unwrapped 16 meshes in both manners and the results were the same so im sure its the method