Yes Shawn, it is easier than you'd think (once again, I am thankful for your input) It has got me excited, but then, it is so easy to get a number of puppets on the way and none totally finished

. because you still have to do the rest of the process of cloth covering, bodies and features... then what to do with them, when one has a thousand other things one must be doing instead?
Yes, I found one layer of tape was fine as long as you overlap it a bit so it stays together, and having it only a layer thick it is easier to cut through.
Vectoring the shapes onto one per page has advantages of being able to scale them to other sizes easily, and printing them page by page, so you can keep them backed up as hard copies, and you can then email them to anyone if you want to.