Now comes the fun part: The skeleton!
Simplify the model until only the outer hull is left. Everything inbetween must go, especially remnants of former ortho slices. Sometimes additional faces are created inside the hull when you are dealing with simple geometric shapes or faces which are parallel, like faces of box-like structures with few or no curves like this one:
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Those faces are invisble at first but become visible during unfolding:
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or when you switch to the half-tansparent view:
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They are not needed and must go:
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Sometimes you see "garbage faces" in Pepakura models which have been moved out of the print area. Those "garbage" is what happens if the model is not properly cleaned up. This is no big thing though, the model will assemble fine, but it is better to get rid of it in order not to confuse the builder.
So with a completely hollow model you are free to determine the shape of the skeleton. If you have a blueprint with cross-sections you may use that as a guide. Create a series of rectangles, group them, move them to strategic points and intersect them with the model:
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To see where the "ribs" are places intersect the "spine" with the ribs:
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Important: Now draw a simple shape on one of the skeleton groups. This will help you with selecting the parts later because they are going to vanish inside the model:
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Remove all unnecessary lines to create clean skeleton parts:
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The little triangle in the top left corner is part of the respective group. Once you make the hull visible again it will become a bit tricky to select the skeleton, especially after offsetting:
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To select a skeleton group just double-click on its respective triangle.