I'm actually quite interested in seeing how this all turns out since I'm doing a Kensei menpo unfold. Also if you're having a problem with the polycount and still trying to retain accuracy, I had exported the Kensei file into an STL instead of a Collada and managed to get away with more detail that Pepakura was able to handle. I'm not really sure why it worked but it was just a relief to see I hadn't wasted my time; keep up the good work.