Help look like pepakura has gone crazy

[CrimosnBronxs]

Help look like pepakura has gone crazy on me
I have unfloded a model of starscream g1 cybertron ship
and it's has doubled it

When you loook at the model you can see a gray model and the color under it
I thought at first it was fliped till i unfolded it and found the 2nd model
now it is doing it with a few other ones I have unfolded and i have no clue as to why I know the mesh in 3d max is only one part so how comes pepakura is turning it into two or is it something i am doing wrong

I need help

 

[Tirick]

The model is greyed because the normals are flipped. It is possible that there is a duplicate model as well (the flipped one likely).

I'm not familiar with 3ds max though, so I can't help you there.

 

[legion]

You have double the faces because 3dmax renders backfaces, which are counted as separate faces in Pepakura. I do think that there is an option to turn those off in Max though.

 

[CrimosnBronxs]

looked into it and still no joy
Have turned off backfaces removed the textures and re exported the mesh still the same thing

Not sure what i need to change

 

[nav]

I've also used blender and there is the same problem.

 

[papercraftcouple]

Did you try to remove the double vertices in blender ? by pressing Tab to go to edit mode the press W and choose select remove double vertices