A retro thread ... Dr._Bunsen_Honeydew is till there and spikes head too. Are you wanting to make a small mouth puppet?  It is as Shawn says, start with your mouth piece, or go with a Plasticine model/masking tape design process. The important thing is to have a seam from the corners of the mouth, joining face to chin pieces, and then sewing mouth cloth into the resulting mouth hole.The rest of the form can then go from there. If the mouth is flush with the face like Dr._Bunsen_Honeydew, you will need to reduce the foam thicknesses around the mouth so the foams compress better when opening the mouth, if the mouth extrudes, you will have a more comfortable hand positioning inside the puppet.

 Just an added note...Shawn does a sterling job of keeping things orderly behind the scenes. But some threads do age and links come and go. It is good when people like yourself read through an old thread and do a summary post.That saves shawn a lot of time and helps the rest of us, as well as yourself. What you can do is write a summary of what you have read and collect all the links you have found still work, and list them all in the same post. This way a new user will open on the last post and get your summary, and it will stimulate new discussion and help. There may even be new and better links that people have come across but have not posted yet. And the info you are looking for, if you still can't find it, just ask. We generally love to help.

Just an added note...Shawn does a sterling job of keeping things orderly behind the scenes. But some threads do age and links come and go. It is good when people like yourself read through an old thread and do a summary post.That saves shawn a lot of time and helps the rest of us, as well as yourself. What you can do is write a summary of what you have read and collect all the links you have found still work, and list them all in the same post. This way a new user will open on the last post and get your summary, and it will stimulate new discussion and help. There may even be new and better links that people have come across but have not posted yet. And the info you are looking for, if you still can't find it, just ask. We generally love to help.

Great idea Philip. And thanks for all the videos you have done. It's really helping my understanding. I'm working on an arts and crafts community and supplies website for New Zealanders and planning to introduce puppet making into our mix. Hence my researching. I'll start collecting some working links and get a post up later this week. Yours will be in the mix.