Very cool model. file appears to be the model from Ironman the video game. I was wondering if anyone has ripped the Extremis or other models from the game?
Sorry I don't have much experience from ripping models form games. If I get any information I let you know. Not sure if you could get the Sith Acolyte warrior model that is in the SWTOR trailers. I would like that model if you can fix your problems.
Definitely a cool idea. You should do the rescue armor suit also since you have a pretty close chest, pelvis and wrist piece. All you will have to do is the helmet.
There is a multi color box at the top left on the tool bar of pepakura. If you click that it should remove any textures or colors added to the pep file.