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One technique I found helpful when putting together large models is to alternate the tabs at each edge. Then they interlock and force the edges to align properly.
This worked quite well when I was putting together a life-sized Deadpool head from a Pepakura file I found.
Interestingly enough. Even though it was a pepakura file designed from flat polygons, I was able to get pretty natural curves in the final model.
Of course Pepakura gives you the option to re-assign tabs if you can open the model in edit mode. Not entirely sure how you could move tabs on a printable file instead.
But that's just an observation from a large size model I made.
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