Had a question about building the puppet mouth but thought I'd do a tutorial on how I do mine.  I've been working on improving the mouth for 4 years and think I'm finally happy with it!    Thought this would help newbie puppet builders and save them some time!

I use Contact Adhesive for all the gluing.

Picture a:
Black felt mouth sewn on to fabric.  Puppet is wrong side out. Four tabs on felt are to position felt before sewing.

Picture b:
Rigid white plastic in 2 halves 2mm thick ( 1/16" I think!). I cut it with scissors and corners are slightly rounded to take away the sharp edge. Any thicker than 2mm is difficult to cut with scissors - any thinner tends to bend.

Picture c:
Plastic is covered with curly fleece fabric to give the puppeteers hand a grip. The side bits of the fabric are trimmed for the glue to be applied to put the foam head on.

Picture d:
Vinyl strap made from the 'table protector' fabric which is vinyl on top and then a thick layer of polyester type padding underneath.  Very comfortable and doesn't stretch like elastic.

Picture e:
The rigid plastic is difficult to source in the UK so in my Puppet Pattern I suggest using Foam Board 3mm thick(sorry can't figure what this is in inches) also cut with scissors and braced with Ice Lolly sticks as it has a tendency to buckle.  Upper half shows the outline to put the glue on - lower half has the stick glued on. 

My question is if you live in a remote place then rigid plastic and foam board are difficult to come by - some patterns suggest single plywood, laminate, hardboard which would be easier to find but how do you cut them in an oval shape?  I'd like to include this in my pattern as an option but would would like to try it first.

Helen

Thank you Helen, A very nice and detailed tutorial. I'm sure this will help all of us. Great picture setup and instructions. Tell us more! 

I like foam core for my mouthboards. It's 1/8 inch edge helps to glue on nip and tuck faces/3 piece heads a bit better, but thats for nip and tuck or 3 piece types.

Thank you for the addition to the site.

Thanks Sonny!

think Foam Core must be the USA name for Foam Board - I used it quite a bit but then one mouth plate bent in the middle so stopped using it but that might just be the design of my puppet.

One day I;m going to try nip and tuck your puppets are an inspiration! 

Helen

Cut wood and other items with a band saw or a router. We put several pieces together (tape them) and go around them with a band saw or router to cut out. I use sentra or another hard plastic and cut it that way.

Have you had a problem with felt holding up?  I use fleece for the mouths because it has more stretch and holds up longer.

You would have to buy a wood cutting machine such as a Dremel Tool with a cutting blade attachment tool added on, jig saw a scroll or band saw.  You could try to use a hand saw but trying to make round edges with a saw might be to hard to do properly and safely.  I understand that you are trying to keep the costs down for people who might only want to make one puppet, but some people may have access to these tools and are willing to use them.  It seems you just want information on what tools you could use to cut more challenging material, I hope this helps to answer your question.

BTW Thanks for the picture tutorial on how to make a mouth plate!!

Daryl H

Great work on the tutorial.............. I always find it interesting the so many different ways mouth plate are design. It looks like your tutorial is right on the money.

Billy D.

Cut wood and other items with a band saw or a router. We put several pieces together (tape them) and go around them with a band saw or router to cut out. I use sentra or another hard plastic and cut it that way.

Have you had a problem with felt holding up?  I use fleece for the mouths because it has more stretch and holds up longer.

Thanks for this - I'll see if I can borrow these tools from someone and try them - the idea of taping pieces together is very good!
I'd never thought of using fleece for the mouth - by holding up I presume you mean staying glued to the plastic - I just have to make sure it's thoroughly glued but think I'll try the fleece as you say it would have more stretch.

Helen

You would have to buy a wood cutting machine such as a Dremel Tool
Daryl H

Thanks Daryl - I used my husband's dremel some time ago but the blade kept breaking however I've looked it up on the web and looks like possibly a router attachment would be better - or I just need to get the hang of using it! Yes I'm looking for info but also to try it out as I don't like suggesting things unless I know it works! It's interesting also to use the different materials and increase my knowledge of puppet building!

Helen

Not a problem,

I think what she meant by the felt with the mouth is felt over time gets very fuzzy and stringy like and starts looking less attractive.

Another great material is Doe Suede (it is fake stuff not real Doe), it is very thin and has a little fuzz feel to it.  I love it and never fuzzes up.

Daryl H

Thanks Billy! 

And thanks Daryl - yes I see what you mean about felt I'll have a look for the Doe Suede too - all this info is brilliant!

Helen