I have a question... and I admit I didn't read all 51 pages of this thread, so someone might have asked this already...
Couldn't the folks that create and/or unfold the pep files just create an additional piece that's simply a 'dummy' piece used as an easy scale tester?
I'm thinking that pep files for helmets, for example, could have a simple band that runs around the forehead level of the helmet wearer. This won't need to be ATTACHED to the armor geometry - it could be completely unconnected to the rest of the helmet... as long as it's where the user's head should be within the helmet.
If that piece was added to the pep helmet file, the user would only have to estimate his/her scale and then print out JUST this dummy piece. The user cut out the band and put it around his/her head. If it fits, the part is properly scaled... if it doesn't you need to adjust the scale by the amount you're off before printing all the rest of the pieces.
I know it means I bit of extra work for the pep file creators, but it seems INCREDIBLY useful for the end user for every little extra work for the file creators.
The modelers would just need to add one extra paper piece to their model (one that most easily would allow for checking the scale of the overall piece).
Suggested 'dummy scale-checking pieces' might be:
Hemlet = head circumference band
Gloves = palm width band
Boots = foot length band
Cod Piece = band around the waist
Arm Piece = Band that runs straight down from the shoulder to the elbow
Etc, etc, etc
Again, I hate to mention this if others have already asked, but this just seems like a very no-brainer way to make it MUCH easier to scale the armor.
Thanks,
Jonathan Douglas