Am i the only one??

im currently building my ironman suit out of foam using the pepakura files online although quiet often im having to alter parts of the foam because the piece is too big or too small. and when i match it to the template its exactly the same... does anyone else go through this same issue???

You have to scale the pieces to your body. Search for pepakura sizing

Not sure what you mean. Are you scaling the pieces before printing? And what template?

I've had to print some pieces out multiple times because I guessed a little on the scale. I've been printing and putting the pep together in paper first, fitting it, and then printing the pieces again and transferring it to foam for the final product. Very time consuming. Also, a couple pieces so far (forearms in particular, and I'll probably have the same problem with the calves) I had to remove a couple sections to make it slimmer to fit better, otherwise it would have been too bulky on me.

The scaling is fine so far im 5"8ft and i have a wierd body type so i have long arms and legs but a short torso so they fit..

But when it comes to put the pieces together they often are to long or short to fit together, I just want to know if it's a normal thing or am i just doing it wrong

Btw sorry if I don't make much sense I'm using my phone and it's screwing around

I think you may not be taking into account the foam thickness. These models where design to be made out of card which has no real thickness.

If you butt them together as in fig2 you will be adding extra length\width which is wrong and your parts won't sit together nicely.

To get the parts to fit as they would in card Fig1 you need to camfer the edges as in fig3.

Hope that helps you out.