Hey P&Sians,

Total eureka moment! So awesome!  I had been wanting to make this character for months but really struggled with the design. Friday night it came to me and today, huzzah, he's finished!

I had originally purchased vinyl to construct him. I've sewn with it stacks and knew it would be hard to do but totally discounted how little (zip) stretch it has. I really want to remake this guy now that I have the design right but have no idea what fabric to use. I need some stretch but not too much in case the shape of the bones skews. I liked the idea of vinyl as it looked weathered. Any ideas on a substitute?

I Love it! Order some swatches of some dance type 4-way stretch Lycra and see how it feels.
 

here is a company that might give you some ideas for fabric types ...Theatre house

http://www.theatrehouse.com/mm5/merchant.mvc?Screen=CTGY&Store_Code=THH&Category_Code=FabStretch

Wow, very nice. Now I am looking forward to Halloween...

Agreed that you will get the most "stretch" from lycra. However, you might want to consider a different fabric with a lycra blend, if you want something matte or you don't have a lot of exposure to sewing with lycra. (It's a pain)

Here's a few tips that may help if you are thinking of going in that direction:

http://www.sew-stitch-learn.com/SpandexFabric.html

I like the fabric you used.   I think that spandex would use but I don't think I would use a 4 way stretch. I would go with a spandex that simply stretched on one plane. You need your stretch to go across not up an down. So say on a leg or arm bone you don't want stretch up and down or the bone would elongate on you from weight. Same on vertical spine. The ribs and pelvic I don't think would be as sensitive.

Thanks for your suggestions guys. Billy I wish you hadn't sent me that link... my bank balance is groaning in anticipation already!

I must admit that lycra and spandex absolutely terrify me. I actually sewed with something similar (a blend of some sort) for a failed puppet recently. It was a nightmare to sew with and I found the seams did not hold well under a little pressure (thus why the puppet has been cast aside for now). But I shall read all your tips and give it another go!

Shawn I don't mind the fabric I used either. It's just an anti pill fleece. Being white and fleece though, it grips everything so I am concerned about keeping him clean long term.

Lizzie, your prototype looks great. I haven't really got any different suggestions for fabric other than something to lycra. Are you planning to use with something like the Dead Terrorist sketch that Jeff Dunham does? (my family loves that one! Our friend in Victoria even sent us 2 dead terrorist mugs!)

I just had a thought. I use liquid latex over felt fabric on my puppets-it might be a possibility for you. I paint it on after hand-tinting with acrylic paint.You can buy it on-line-it's often referred to as paint-on latex.

What Clewer said. If soft-bodied wasn't super essential, I'd be more inclined to be working with liquid latex as a skinning material, over portions of foam that had been "wrapped" in some manner. There are a lot of SFX websites that could be a good resource, think more Skesis than Fraggle.

Skesis as in the Dark Crystal? That would be ideal. Thank you both. I have never heard of this product so will definitely need to do some research - it sounds amazing and a great alternative for me, particularly if it means I don't have to build him again! Wow, I really have SO much to learn about puppet building. Thanks again for your help.

Deb, I haven't seen the dead terrorist sketch. I try not to watch too many puppet videos believe it or not as I find their brilliance kind of zap my confidence.  I'm working on a script though that will involve all my puppets and there are more to be made to see it come to fruition. I am in no way a performer (except at home!) so am incredibly daunted by this but also excited to actually have something to work towards.

Thanks again

A walking foot on the sewing machine can help with spandex and Lycra. Also you want to use a slight zigzag stitch or else the seam tends to pop on you when the fabric is stretched. 

The needle is important also. I think it is a ball point you want but for some reason at the moment I am not sure of that... maybe someone can confirm that.

Here's Dr. Megan with a video:

<a href="http://www.youtube.com/watch?2McSZdOazCE" target="youtube">YouTube Video</a>

I would have mentioned an overlocker as a potential solution for sewing stretch fabrics but it seemed irrelevant with the possibility of liquid latex as a covering option. However, if you have a friend who owns one it would be a very useful thing.

Like him! He would make a great blacklight  puppet.  White antron glows and resists dirt and such much better than anti pill fless.  That is what we use if a puppet requires white even if it's not a blacklight puppet.

They do make stretch vinyl, 2 and 4 way stretch.  Most I've seen is shiny, but it might come in matte.

Julie