Is it really necessary that you make up so many new threads? Most of your questions could have fit just fine in one thread. Look up billybob884 on Deviant Art for all your Fallout Pepakura needs.
Yes, I believe so. The weapon is as it is ingame. It is a useful template for the pep base, but I agree that it does have wasted faces. This seems to be a common element in game models.
If you have the files from FO3 I'll take them if you have them. My friend and I are working on getting better at the whole editing process. Also working on and entire Skyrim outfit for Halloween this year and to use at the Rennaissance Fair.