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I've been sitting on this model for some time now, over a year actually, and I've come to the conclusion that I just can't seem to muster the drive to finishing it. On the other hand though, I have already done most of the design work, and it'd be a shame to let it go to waste, so I've decided to post what's finished with a disclaimer:
THIS IS AN UN-TESTED MODEL.
From what I remember, I had already given it a first pass, but there will probably still be a few kinks, and any prospective builders will have to deal with them on the fly. If you do give it a try, feel free to share your experiences or others to learn from!
I had to do a lot of work on the textures and mapping, it seems like it was designed to only look good from a first-person perspective, as the back was a mess. I did my best to touch up the seams, but there are still some rough spots. If anyone is interested in trying their hand at it, I'll post the texture file.
The scale was a bit harder to figure out; the model relative to Chell is actually huge, at least half the length of her arm, and probably would have weighed a good 15lbs (~7Kg), where as a real potato is closer to 4" long and less than half a pound (~200g). I settled on something in between, largely for practicality's sake: 6.5" (16cm) wide X 8.5" (22cm) high X 4.5" (12cm) deep.
PDF of Pieces
PePaKuRa (PDO) Files
On a side note, where the hell are you supposed to post .PDO files? They have several categories for papercrafts, but none accept anything other than plain images... I've been having to throw them in one of the miscellaneous/tutorial categories...
I hope you'll make GLaDOS from Portal 2 and Wheatley.