Its been a while since ive done anything with puppets and its depressing so i thought id come back and see if i can get some opinions.#1 Some of you have told me about draping when it comes to making a head pattern from scratch. i personally am too freaked at the thought of cutting too much off and getting messy results or making way too many darts. is there a certain way that you would tackle a situation like this?
#2, when you make darts on foam and fleece, do you make triangles or rounded wedges?
In this picture you can see that i make nearly 90 degree angles to give it shape but it always causes the seam to bump out, like the dimples on the sides of a puppets mouth. i need to know how to get the best cut so it will be more rounded. to anyone that can help, thank you.

In answer to your first question,  you might want to try using the same pattern as you used with your foam. You would need to cut the fabric about 1/8 to 1/4 bigger to allow seam allowance. Use an old t-shirt to do this at first since it should have a stretch that is close to your fleece.  Put your template over the foam head and see where you might need to modify things. Since it is a template you can even use markers to draw on the fabric to give you a guide where you want to re-sew.  Do this till you get what you want. Then take your template apart and (use really big stitches when putting together to make this easier) and you have a pattern for the real fabric!   If you want to try your hand at drapeing use the t-shirt material to do it and again you have a template you can turn into the pattern if you get what you like.  Since t-shirt material has no nape to it, if you get a fairly clean smooth look then your fleece is really going to look nice.

The answer to your second question is Yes triangles, Yes rounded wedges.   You use a combination of both. Easing out that bump does take more of a rounded wedge if I am understanding what you mean by that.  Instead of the straight 90 degree cut you round it some either in or out. Curveing out should be for the top of the head where you have an outside curve.  If you need to create an inside curve then you curve in on your triangle/wedge.

When I built my first puppets I was worried about wasting valuable fabric with mistakes so I did the t-shirt pattern thing.  If you're patient and persistent you can get a nice smooth coverage with minimal darts.  With time you'll become confident to skip the pattern and work directly with the fabric.

Very true jon, and as always you know best shawn Im glad you totally get what i mean, youre awesome. I guess ill make some wedges now that i know its ok. One thing about that though, If you make a wedge, do you have to make it bigger than a dart to cut out the correct amount of foam?

Well yes and no.   Since you are curveing the line you do end up cutting a bit more foam from the outside edge of your foam sometimes.  In the pic you provides most the darts could stay close to what you have on the outside but a couple of them look like they are pretty small to start with so they may grow some. Then again some of those smaller darts may not need to be curved.