It’s the Bevel modifier; you’ve got its display set off in viewport. Change that and it’ll look just as ugly as in the render. I haven’t ever used the modifier, but I think you’re better off applying it and then re-unwrapping.
Shay: I have looked at the file and the image is not packed in there. Can you please re-load the blend with the image packed or upload the image? You could also try cube instead of flat projection. I don’t know if that will help but it’s worth a shot.