Normally gasket rubber is better used for the mouth plate but you could perhaps use it to add support for small areas in a puppet on the inside.

Ohhh, I see what you talking about!  Thanks guys!

Gasket Rubber is used for all type of applications




Billy D.

Great! More visual!

@Billy D. Oh ok, thanks for the information and link! And it's good to know they cut it for you, I was worried because I thought they were too thick.

@Chris I think I did try Kragen, but I didn't ask, I just looked around and didn't see what I thought I was looking for. But I'll try again, thanks Chris!

@Shawn Ah ok, that does make sense. And would using the same regular upholstery polyfoam still work out for support beams? Or would it be better to use a firmer foam?
And that does make sense, thanks for the advice Shawn!

Another very light weight foam that would provide great support would be those noodle things (http://www.spongexfoam.com/planet-foam) that are sold for swimming pool fun and games.  I think they are made out of ethafoam, or something very similar. They are pretty farm, but not brittle like styrofoam. Very, very lightweight. This is a great time of year to look for them, I picked one up on a summer clearance sale for $2 at my local supermarket. They cut very easily with a razor blade.

Also, I bit the bullet and was very non-man when I got my gasket material. The nice lady asked if she could help me find something, and I actually said yes! It probably saved me 20 minutes! 

For support beams I normally try to find a firmer foam.  I buy what is called EVA foam (at least by my foam supplier)  which is very high density. They say it is used mainly by boat makers and such since it does not soak up the water as bad. I even often use it to make the entire head or for the body since it is much more rigid. You may not be able to find it but if you can find a denser foam it might be good for supports.

I saw Chris's post after I posted... the noodles are a perfect example of what the EVA foam is that I buy although a bit different.

@Chris Oh that does seem like a great idea! They're selling tons of them at the Dollar Stores in my area, I think I'll pick up a few more and try it out.
And I ended up finding the gasket rubber on my own this time. I asked for help and the guy said they had gasket paper. I gave him a funny look and he led me to where this thing was. It WASN'T what I needed but since I now knew the gasket rubber came rolled up I found it in a shelf close by!

@Shawn Is EVA foam like ethafoam? As in the same material use for pipe insulation? That does sound like something worth trying!

so Ive been toying around with this idea for a weak or so, but haven't been able to try it yet....A few weeks back i was refinishing an old cherry desk.  When I poly coat a piece of furniture that is cubed I will do one side a night to aviod having the clear coat making runs, plus it levels itself quite nicely.  Any who, a desk with 7 sides each needing at least 2 coats of poly at one night per side per coat starts to take up some time.....so i started to put my wet foam brush into a ziplock so i could get a few days use outta of each one.....after a few day they would become as heard as bricks, but remained quite light....a few days later it hits me.....the brush and the foam i use to make puppets with are chemically the same...in theory once a head is finished it could be completely or partially glazed in several layers over a couple of days with polyurethane to produce a lightweight almost rock hard form.....quite possibly to the point where some sanding and forming are possible!   I think doing an initial coat would seal the foam and any coat afterward would be insubstantial....so at around $30 a gallon you could use the method quite liberally.  But like I said this looks good on paper but has yet to be field tested......

Hmmm.... Polyurethane as a finishing coat for foam puppets.  That is an interesting idea. The only drawback I can see is that it would leave the foam stiff and un-flexible but depending on where it is used and on what type of puppet you are making it could be a winner!