This thread is the primary reason I've joined these forums, actually - so let me do a quick rundown of why I'm here before I get to asking questions.
I'm a costumer. A TransCostumer, to be precise, and have made models of my costumes for my reference when building in the past (I'm in college for video games so I've got 3Ds Max, Maya, UDK, etc.) I've done a Movie!Brawl costume, and ever since then have really wanted to be a WfC Brawl. However, knowing I could actually get a model fairly close to what was in the game was more tempting than anything else, so I've held off on it in the hopes that the model would be captured at some point.
Ok, so now let me get on with the questions and such. Number one, where are you guys at currently? I've read thru the thread and looks like there's been issues and resolutions galore, but I can't keep straight what people need help with. Specifically, given time, I can fix or entirely re-model a mesh. I'd love to help you guys out (I know others who would like to do WfC Megs and Optimus), so give me a place to start helping.

If you're curious about my past experience with pepakura specifically, I've helped Nintendude of the 405th forums create, and fix a few meshes over the past 6 months. I'm also in a build of the Mark V Mjolnir armor from Pep files at the moment.
So if there were any questions still open regarding 3D stuffs, shoot again and I can certainly tell you what's up, or otherwise try to find a solution.

I'd love to see a whole library of these guys online someday.
edit:
It looks easier than the soundwave to clean up.. do you think it's possible to get soundwave and the chair separate?
Yeah, just like you can get Laserbeak off of it too.