Sounds like we should be on each others panels, lol. I'm doing Pepakura (Papercraft) for Costuming and Propmaking. But all I can bring into the field is either pepakura, or making patterns from scratch. Like when I made my Helghast, I found a ortho photo online, then traced the armor with Paint Shop Pro. Then I removed the background ortho image leaving me with lines, and imported the images into Posterazor for enlarging.
Pepakura is just a base, of course I've seen people do amazing things with just paper, fiberglass and bondo. But others have used the process for foam armoring, sintra, etc. But with my 6 years of expertise with it there's too much to cover in one post.