being a bigger guy, I run into this all the time, I usually just use the "join/disjoin face" tool to make smaller pieces that will fit on one piece of paper (if I can). For pieces that I can't cut, like the long support struts on the HD MK VI chest by flyingsquirrel, I use my ruler (after printing the file) to connect the page orientation marks that print in the corners on both of the split parts, then as I cut them out I make a tab on one of the two pieces, to make putting them together easier... I haven't noticed any size differences