Here's something that I've meant to post for a while: It's something that I started building a few months ago and have stalled on a little bit. Mostly that's because the show that it was being built for fell through, but also because it's been too cold to paint outside. The project was to make a giant head with moving eyes and mouth that could swallow smaller puppets and cry them out.
I started with some design drawings, then moved on to a full-scale pattern in full view and profile:

Then I started laying out little wooden beams in squares and rectangles. They're easiest to build:

Things got more complicated when I moved up from the flat construction, but it's still basically the same thing:

Here it is with even more wooden beams:

And here with the separate jaw piece built:

Once I had the wooden frame, I started to cover it with foam sheets. I didn't really measure that much or make a pattern here, I just eyeballed it. In some places I used extra foam to bring features out, like the lips and chin. The nose is thick foam laminated together and carved with scissors and electric carving knife:



Then I spray-painted it grey as a base:

And finally I built a stand for it:

Now I need to wait for the spring thaw to be able to paint more. I also need to figure out the eyes, but it's not really a priority right now. In a few more weeks, perhaps.