So the problem with the helmet is that the hole at the bottom is not wide/long enough? I'd really like to fix this so others don't have to split this helmet in half =\ It's really a matter of grabbing one side and pulling it with a soft modifier. I just need to know what's wrong with it D: and I don't really understand the extra flap thing you're talking about. Do you have a photo example? perhaps a screenshot of the pep on computer.
Hope you can help me out.. I'd like to fix this before more and more people download.
I think you're bad ass for being to open to suggestions. I want to preface my comments with, I in no way can do what you do nor will I ever say anything hurtful about the 3D modeler community here at the 405th.
So will all due respect and humility here are my very retentive comments that might help further revisions of this helm:
For what ever reason there are ALL flaps along these seams. Easily cut off and corrected, but a weird little thing that I came across.
Along this seam is the majority of the reason a person can't just slide this helmet on. From the chin to the nape of the neck is "ok" length wise, but the width is where I think most people will have issues.
The section of paneling behind the 2 jaw intakes look like they could be more laterally rounded out, which would save/fix the issue of sliding it on without having multiple pieces.
I hope this helps. Also, I would re-edit the unfold so all the areas where a fold and seam are virtually in the same spot no longer are close or connected. It means there might be more pieces to cut out, but at least all the seams would marry up and not have to be glued on the "edge" of the paper but on the flap. People can obviously fix this themselves, which I didn't do until I had already almost finished the helmet 2x, but if you want to have a perfectly polished model and unfold, these are my critiques.
Again, please don't take anything I said personally. I am very impressed you are interested in going back into it a 2nd time and tweaking things. I definatly have little to no idea of what kind of magic you guys do to make these pep files possible. *salute*