yeah, THAT is something you have to get used to, I know I did. lol... What I would do for questionable pieces, (such as the MK VI torso) is only print off a part first, like the immediate neck and collar area, and build and fit that. If it fit, I would print off the rest of the parts, if not, then I only used 2 or 3 sheets of paper instead of 30 or 40... (also, if you find a piece is not going to fit before you finish pepping it, just take the left-over sheets of paper and re-print using the backs of them) Thats why I only cut out the parts as I come to them in the build.
oh, look here in mexico there is also something called Fomi, that i missunderstood with foamie, that's what i was talkib about, FOMI is something very similar to the Mouse pad thing, maybe you can cut in layers " like Dragon scales are made of " and out one over each other =P and paste them with Hot glue or omething, all of this over a suit of neoprene or something similar, thoses neoprene suits are not that expensive as i know, but you will Sweat a lot ... lol that's Hot XD
and i'd be glad to help you out! any questions just throw them my way and i'll try and answer as best i can, also checking out other wip threads can help you, thats how i learnt most of the stuff i know now :D