For those of you playing the home game; no, I have not discarded my desire to do Darth Malgus. In fact with a few recent aquisitions and some notes online, I'm re-doubling my efforts to progress towards obtaining my "Sith Lord" designation in the 501st.
Just putting a few links down here for future reference for this project...
Pepakura Notes and Tutorials
Fierfek's Pepakura Files - Has Some Malgus Stuff
EVA Foam -> Rotocast Finish
This could be...interesting.