Question:
Is there an easier way to cut pepakura lines than spending 45min using an X-acto knife to cut out a piece this small? Or is this normal?
You can save time by cutting outwards from all these little corners between the flaps - hitting the corner precisely is important, but the shape of the flap usually doesn't matter, unless the flap is awkwardly angled to accomodate the neighbouring face.
While a lot of members attest to the great use of X-acto knife, might I suggest using a scissors? Believe me, a medium rubber grip scissors can speed up the process. In most pep files, you do not have to be 100% accurate in your cutting. The tabs, as Ventrue said, you don't have to be exact. As for the edges that you need to stick together, you can have better control using a pair of scissors. No rulers are needed. Again, you don't have to be 100% accurate. Once you pep your pieces, more often than not you will apply resin and rondo over it. When I first pep MK VI - HD helmet, it took me almost 20 hours because I tried to be perfect. Now, I can finish pepping a helmet in less than 5 hours.