Batgirl pepakura help????

I've been trying to make a Batgirl cowl for my five year old daughter. I have about three or four different pepakura files I can use. I get her head measured, change the inches to mm, change the scale in pep designer and print. Ever time it comes out small enough to fit her dolls.

Any ideas what I might be doing wrong? This worked perfectly on a Capt America helmet I made for myself a couple days ago.

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I had the same issue last year building my daughters Batgirl cowl. What I did was just kept messing with the scale of just the part that went around the eyes. When I got that part right, I went ahead and printed out the rest the same scale. Worked for me. Good luck.