Yeah sorry about that... in Blender it seemed really simple, but when I export it I guess it changes to tri's
Ain't the tris, mate. Tris I can deal with. Now that I've gotten into the file, I have a few more things that I'm having trouble with though. I'm sorry for the harshness of this critique, but my goal is your improvement as a modeler for pep. Some of these pieces are literally unpepable. Not just, "you wouldn't want to pep them", but "paper cannot physically fold that tightly". The rim around the visor on the top is less than 2mm thick in some places when unfolded to normal size, cardstock can't hold a crease that tight. (Not to mention that the tabs for attaching parts together are more than twice that size. Same goes for the lines between the plates on the top of the helmet, in the visor, and around the ear. The valley is too steep, the paper will bend outward and cause warping, even if perfectly assembled. If this was a game asset, all this stuff would be fine, but you have to keep in mind that essentially every single poly you put into this model has to be cut, folded, and glued together, and the more contours and complex shapes you put in, the harder it is to actually construct. There are also a lot of places where things just aren't QUITE flat, meaning that it has to be divided up into twice as many pieces when being pepped. You also have some verts that dip inside the solid surface of another polygon, and that's a big no-no for pep. I hope some of this helps your modeling, you have great potential for making this stuff, and you've made some great files, you just need to dial down on the HD and learn to work with the limitations of pepakura and paper building. I suggest you get down and assemble a few HD pep models yourself, might give you a good sense of how to improve your work.
P.S. Grooves are the worst to pep. Ever. My personal philosophy is to let the builders do those later on in the detailing phase. It's a heck of a lot easier to go in with a dremel or bondo and make grooves than to try and build it that way from the start. They never turn out right in paper.
P.P.S. There is a reason all the visors on pep files on the site are so low-definition. They just get cut out afterwards. What's the point of spending several hours (yes, building that visor would literally take hours) on the visor, when it won't be of any use later (aside from making a vacuum forming buck, but it would need extra work even then).
P.P.P.S. I've taken a break from trying to unfold this thing, if anyone else wants to take a stab at it and thinks they can do better than me and actually finish, please do.