I took @3DPremium Storm Trooper and made in full size. 

Why this big you might ask?
Easy. Why not?

Follow these steps to assemble:

A number represents a part file number.

- (46) + (47)

- (67) + (68)
-(70) + (71)
- (42) + (43) + (44) + (45)
- (46 to 47) + (48)
- (54) + (55)
- (61) + (62)
- (67 to 68) + (69)
- (70 to 71) + (72)
- (74) + (75)
- (18) + (19)
- (21) + (22)
- (29) + (30)
- (38) + (39)
- (40) + (41)
- (42 to 45) + (46 to 48)
- (51) + (52)
- (54 to 55) + (56)
- (60) + (61 to 62)
- (63) + (64)
- (66) + (67 to 69)
- (70 to 72) + (73)
- (74 to 75) + (76)
- (77) + (78)
- (79) + (80)
- (17) + (18 to 19)
- (20) + (21 to 22)
- (24) + (25)
- (26) + (27)
- (29 to 30) + (31)
- (32) + (33) + (34)
- (35) + (36) + (37) + (38 to 39) + (40 to 41) + (42 to 48)
- (49) + (50)
- (51 to 52) + (53)
- (54 to 56) + (57)
- (58) + (59)
- (60 to 62) + (63 to 64)
- (66 to 69) + (70 to 73)
- (74 to 76) + (77 to 78)
- (79 to 80) + (81)
- (2) + (3)
- (9) + (10)
- (17 to 19) + (20 to 22)
- (24 to 25) + (26 to 27)
- (29 to 31) + (32 to 34) + (35 to 48)
- (49 to 50) + (51 to 53)
- (54 to 57) + (58 to 59)
- (60 to 64) + (65) + (66 to 73)
- (74 to 78) + (79 to 81)
- (83) + (84)
- (85) + (86)
- (1) + (2 to 3)
- (5) + (6)
- (8) + (9 to 10)
- (12) + (13)
- (17 to 22) + (23) + (24 to 27)
- (28) + (29 to 48) + (49 to 53) + (54 to 59)
- (60 to 73) + (74 to 81)
- (83 to 84) + (85 to 86)
- (1 to 3) + (4)
- (5 to 6) + (7)
- (8 to 10) + (11)
- (12 to 13) + (14)
- (15) + (16) + (17 to 27) + (28 to 59)
- (60 to 81) + (82) + (83 to 86)
- (1 to 4) + (5 to 7)
- (8 to 11) + (12 to 14)
- (15 to 59) + (60 to 86)
- (1 to 7) + (8 to 14) + (15 to 86)
 

It's fully printable with dowels between each part for easier assembling and glueing.
No, I won't print it but maybe you will?