Very interesting. That has happened to me before too. But I just followed the steps in the video again and it worked. So I think what might help is this. Once you change the settings, go through each map FOR EACH TEXTURE SET (bodymat and eyesmat) and double check that the settings really did change. In substance painter, it's possible to make it so that changing the settings for one texture set doesn't change the settings for all texture sets. I think because I've done it once before on my computer, the default settings might be set up correctly. So go through each map for each material and double check that "only same mesh name" is set correctly. You can also check the "common settings" menu at the top of the list of maps to double check that "match By Mesh Name" is set properly for both texture sets. Lastly, you can also try re-baking all the maps and not just Ambient Occlusion, Curvature, and Thickness. Just in case the normal map and worldspace normal were also "infected" by overlapping with the body. That's because if the "max frontal distance" of the cage is set large enough, then the normal map might get some artifacts baked in where the meshes overlap. And the curvature map is based on the normal map. So rebaking EVERYTHING after the settings are changed could solve your issue. Let us know if that helps!

@@MikeSmith3D you are a legend. Thanks man