Howto :
http://www.wintershade.com/therpf/printalignmentmarks.gif
After having ticked "print alignment marks for multiple pages" in "setting / print setting", you can print your pages. Then, cut away the top and left margins of each of them, and then tape all of them together to obtain a laaarge single page.
Then, cut out your paper pieces just like they are.
If these pieces are too large for your foam hight or width, you'll have to choose between cutting your piece of paper in smaller parts to match your foam sheets size, of seaming multiple foam sheets to obtain a single and large enough foam sheet to match your paper piece size.
Step by step :
Be sure to set A4 or Letter properly, or you'll run the risk to print outside the paper.
You should tape the sheets before cutting the patterns :
1. print your sheets
2. tape your sheets
2.1- match the alignment marks
http://www.wintershade.com/therpf/pdotape01.jpg
2.2- tape the corners
http://www.wintershade.com/therpf/pdotape02.jpg
2.3- tape the whole meeting sides
http://www.wintershade.com/therpf/pdotape03.jpg
... and only then you can cut up your masks. This way you can instantly notice if something's wrong before cuting and before taping, and It prevents both hazardous taping and multiple pieces parts spreading.
3. cut your paper masks
4. cut your foam from the masks
5. you get less and bigger foam parts, you save gluing time, and less junctions means nicer curves an inproved "anti-aliasing".
http://www.wintershade.com/therpf/darkvader.jpg
Dark Vader helmet - foam unfold JFcustom.pdo