Base mesh has progressed a bit (but not fast enough).

I’ve been spending precious time experimenting with generating normal maps but had very little success no matter what settings I use. The maps seem to have either nothing on them or to have lots of lines from the low poly mesh, maybe someone can advise me on the best way to do this. I’ve read almost every tutorial on the subject now and my head is mince.
So far I’ve tried taking smaller sections of the model into ZBrush for sculpting e.g. the faceplate (see below), I thought this might work better than taking the entire mesh across especially at this experimental stage (does anyone think there is any merit in this method?).

I’ve been exporting a high-res mesh back to Maya from which I’ve tried to generate the normals but success eludes me at the moment. My enthusiasm is undented however and I’m banging on anyway in the hope that I’ll work it out somehow.