No mate.

The problem was my uvs were sitting exactly on the outer edge of the 0 - 1 space in the uv editor. I found out that zbrush doesnt like it. So I moved the uv's in a bit and it is all fine now.

Yeah with the projections do them a bit at a time and then save out separate maps and then correct the colors etc in ps and put them all together there.

cheers
J