Your models are absolutely great and i would love to build some of them, but i'm not able to do it without the tabs. I really tried but it takes a huge amout of time to draw them myself and even then they don't fit well. Is there a way to add tabs easily, a 3d Model to import into Pepakura or would you share your technique to assemble them without the tabs?
Probably the best way around the tabs (and avoiding the fitting problems you mention) is to take a small strip of paper (I use the scrap pieces left over from earlier cuts), score it (so that it bends to fit the joint) and glue it to the INSIDE or BACK of the joint (where it won't show).
You save yourself some time drawing, actually make the joint stronger, and can make the "tab" as large or as small as you need without screwing up the seams.