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Rhugha
File :-(, x)
My way might be somewhat unconventional, but here's how I've done it.
-Quick sketch in 3D software of your choice. -Import to pepakura designer. -Unfold, then copy development into clipboard. -Paste in e.g. photoshop. -Change all the flaps to the side they are supposed to be glued to. -Copy development again, new layer in photoshop, 50% opacity. -Change the size of one of the opposed flaps.
tl;dr Have flaps everywhere, one of the opposed ones shorter than the other so you can cut into the longer one and insert the short.
Here's the finished testbuild of my creation btw. http://img521.imageshack.us/img521/1188/dsci0001pe1.jpg
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