For anyone interested I've added a few more images in the original post - shots which, I think, do a bit more justice to an area I've put a lot of work into.
@mc_axe Thanks for the praising dude.
I've used hard edges only where a bevel would add more polys without any value, that is inside holes and for the split between "stiches". For these cases I used to disconnect those edges, but when I've reached the "rigging" part, more precisely the skin editing, I realized that having them disconnected adds a bunch of unnecessary points which made my life a lot harder for editing weight values. Thus I've started a point/edge welding frenzy in the middle of the rigging process. As you'd expect not everything matched with their everything and some UV fixing was in order after that. And only then I went back to skin editing and posing.
UVs created inside XSI, yes - used Unfold and other "normal" tools inside the UV editor.
4 tiles horizontally (u_1,2,3,4; v_1) and 8k maps. 4k should've been enough probably, but I couldn't be bothered to downsize them since I've experienced no issue regarding their size.
OK, so let me know what print-screen you want exactly.