I don't do foam... but most folks tend to use Armorsmith to make an avatar that matches them (that's where your measurements come in).
Then import your models and size to match your avatar.
Then export the resized models.
And yes, Armorsmith handles PepaKura files.
I personally only do this with 3d print files, but the process _should_ be the same. I'm sure someone that does this with Pep files can jump in with more details.[ATTACH=full]349497[/ATTACH]