Fantastic work Papermate, If you glue the sheet on a 1mm card it becom in a piece more than 1mm, your pieces seams less than 1mm, (seams to me by the pictures) and the head you will need 0.5mm card or 200gr to glue the sheet. I tried not to have lot of piece for the head becouse as you said thats a lot of work, but in the 1:25 scale will be more pieces. Soon its goint to be available the Soviet pilots!
regards