1/2 inch should be more then enough for a hand puppet.  I think  you'll be ok.

By the way, on the topic of sewing fleece, I've had much better success with "anti-pill" fleece rather than "blizzard" fleece. The "blizzard" fleece is too smooth and doesn't hide the seams as well.

As for hand stitching, I most frequently use a baseball stitch, throwing in a locking stitch as needed, depending on what I'm sewing...

- Sean

I use 1/2" poly foam almost exclusively. Works pretty darn well. It will be plenty sturdy as you shape and glue it.

Sean,

Are you sure it is the baseball stitch that you use and not the ladder stitch?  I've heard folks say they use the baseball stitch before but it is a very visible stitch unlike the ladder stitch.

Yup, I cross under and up through opposite side.


Image from Project Puppet Tutorial Page

My standard stitch spacing is about 1/16", and I don't go in more than 1/16" from the edge (3/64" is typical, depending on the condition of the fleece edge). Again, I typically throw in a lock stitch (loop the thread back through) whenever the fleece is pulling apart, when I'm in a corner, or when I know I'm going to stop for a bit.

I start off with a quick twist knot from the back side of the fabric, and I use only SINGLE threaded stitches on fleece.

Perhaps the ladder stitch works better on "blizzard" fleece? I don't know, I don't use blizzard anymore.

- Sean

Ok... cool!  Just wanted to make sure we where on the same page about stitches.

Yea I think maybe the ladder stitch is better for fabrics that don't have as much nape. For example I can use it on lycra and it hides the thread completely in the fabric.

Billy - I've had one of those bobbin winders for a couple of years. I love it.

Anytime I sew (puppets or anything else) I fill several bobbins before I start sewing.  Saves lots of time and frustration.

I've been teaching sewing classes (again), and have 2 Brothers, 2 Kenmores, 2 singers, a White, and my personal Bernina.  I just picked up another one at an estate sale for $5, don't remember the brand.
I've sewn  puppet or two on all of them to acquaint myself with the machines. My suggestion - keep them oiled and clean according to manufacturers suggestions. Also, cheap thread causes lots of problems.  You will spend more time messing with cheap thread problems than you save in $.

Billy - I've had one of those bobbin winders for a couple of years. I love it.

Anytime I sew (puppets or anything else) I fill several bobbins before I start sewing.  Saves lots of time and frustration.

I've been teaching sewing classes (again), and have 2 Brothers, 2 Kenmores, 2 singers, a White, and my personal Bernina.  I just picked up another one at an estate sale for $5, don't remember the brand.
I've sewn  puppet or two on all of them to acquaint myself with the machines. My suggestion - keep them oiled and clean according to manufacturers suggestions. Also, cheap thread causes lots of problems.  You will spend more time messing with cheap thread problems than you save in $.

Good tips!

I second what MsPuppet said about avoiding cheap thread! Guterman has worked really well for me, and I purchased this set a few years ago:

http://www.joann.com/gutermann-natural-cotton-thread-set-100-colors/prd23404/

It almost ALWAYS goes on sale the day after Thanksgiving at Joanns for $79, and it's a great price for 100 spools of good thread. (Plus, you don't have to worry about finding matching thread when you buy your fabric).

Okay now THAT thread cabinet is kind of awesome!