Here I have my first try:

1.


2.


Hoping help!

Miguel!

Yeah, I know! When I saw yours, I said: She was reading my mind!   

You are good in this! And I'm still learning (Even, figuring out how to make patterns. That's why I ask for pattern, to learn for  )!

Guys, this is really great! I think we're getting somewhere now!

I've glued the foam together and took some pictures of what it looks like. It's definitely a bit too big. Here are the pics, though:

http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/DSC05455.jpg

http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/DSC05456.jpg

http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/DSC05458.jpg

Now, the size of the fleece covering that I'd like to use, if possible, is this (this is a pattern I came up with a little while ago):
http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/wembhead3.jpg

That yielded this, and I think it might be pretty close:
http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/DSC05443.jpg

And, as I said a million times, this is what I want the final product to look like (i've seen lots of pics of wembley puppets, but this one is the absolute best looking):
http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/DSC05443.jpg

http://i3.photobucket.com/albums/y84/haleybrooks/Fraggle/fragglea.jpg

I hope this helps. I know I'm a bit useless when it comes to this, I'm still learning. Thanks again for all the help. Please let me know if you need anything from me. This is a better job than I could ever have dreamed to do.

Hmm... My intent with the cheek being too big was to make it force into the smaller area and make it pouch out like the up close screen cap.
I will look more tomorrow.  Maybe the mouth plate would force the shape into place, but I bet that cheek needs a dart to shape it right.

Revised again.  I changed my mind about the cheek and neck dart.  The mouth opening is one big dart and the neck dart doesn't actually appear to be on the screen caps.  The cheek should fit into place now and not be too big. I added the mouth plate. There are still red lines where more could need to be added to keep the head from getting too narrow (one and a half to two inches total - so about three quarters to one inch on each pattern piece, like a seam allowance.).  I did make the pattern a bit smaller again to help with the scale.

I hope this is more useful.  I am doing this all in my head.  I've actually been pondering if there is any math that can figure out just how much sprong foam has. Like when you release a dart and it pops open. Sprong. It's a good word.

http://rapidshare.com/files/263881035/fraggle_head_rev_2.pdf

hah hah. Believe me, you're doing a great job, better than anything I could ever do, and your help is more appreciated. I can't figure this stuff out on paper, so it's amazing that you are doing it in your head!
Thanks so much!

Do you know who made the puppet that is dead on?  It might be good to ask some question of the creator of that puppet.

Meg

the person was named Red Freggle on photobucket. I tried contacting them through a forum that he posted on, and through photobucket, but no luck.

I thought it might be worth a shot.  As you notice, most puppet people are more than willing to share what they know. (and in my current case what they don't ) 

I will keep working with you until we get it.  If all else fails, when my little ones are at grandmas next month, I'll break out the foam. I would do it now if there wouldn't be shrieks of terror from my 16 month old son.  He despises puppets and all puppet related materials.

What puppet is that?