This has probably been addressed elsewhere, but I have a questions.  One of the hardest things I find about building puppets is attaching the mouth boards.  I use dense cardboard and/or 1/2 inch foam and hot glue them into place.  I have to be very careful in doing this as the glue is hot (obviously) and can be messy and ruin the look of the mouth if it gloops and globs. 

Is there any other technique that others use?  I can't use contact cement as it gives me tremendous headaches even when ventilated.

Any suggestions will be appreciated.

First you can purchase a chemical mask/respirator from a home improvement store.  They have several kinds rated for dust, chemicals etc, so just make sure to read the mask specs.  We always glue outside, use surgical gloves and masks. US prices for the mask are about $35...worth the investment for your health.

2nd...use a thicker plate medium such as foam board or sintra plastic.  If you choose to still use a glue gun get one with a fine tip.  This is my favorite.  I usually have one to two of them plugged in all day (don't leave them plugged in if you are not in room, just in case) They last a really long time 1-3 considering the amount of use and price. 

3rd...work in very small sections...1" at a time until you perfect the method.  If I have to hot glue foam to a mouthplate I sit in front of a tower fan (more concentrated air).

Hot gluing can be more time consuming than contact cement, but start slow and build up the amount of area you hand secure while waiting for the glue to cool...usually the length of your hand.  Practice, practice.

Hope this helps.

Julie

Thanks.  Helps a lot.

Corrogated cardboard did not hold up a long time for my use,it bends on the lines and gets "soggy" soft in high humidity. I use laminated pressed cardboard from Cereal boxes for small hand puppets. Laminate by glueing (Elmers or wood glue thin amount) a couple of layers together under a heavy flat object to make it dry flat.  Paper products will curl when glued if you do not apply moisture evenly on all sides or press under object while drying.  For a small puppet two layers will still give you some flexibiliy and still be thin enough to sew thru it too.  I have not tried to make puppets as large as yours with more layers of pressed cardboard. For large puppets I have used foam core board and with time they sometimes crack, but they are lightweight. I like to use old VHS boxes clear hard plastic, takes some muscle to cut out with heavy razor. I sand the edges to make smooth and sand the sides so hot glue with stick to them. Used to get them at Costco but can't find them anymore.  I hear sintra is wonderful if you can afford it.  I have friends in sign painting business who use it and love it. I am begging them for scraps they cut off the corners for rounded signs. Bought a thick piece of leather from Tandys and want to try that next.  Still searching for the perfect mouth palate.

This makes very good flexible mouths http://www.homedepot.com/h_d1/N-5yc1v/R-100343454/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053  Don't pay attention to the price. WOW.  You can by it in the store by the foot.  I think it's about $5.50 a foot.  It is 5' wide, so with one foot length you can get a good number mouthplates. But, since it is really thin to make it easier to attach the foam cover it with headliner foam/fabric.  It's about 1/8" thick, so if you add it to both sides you will build up the vinyl without loosing the flexibility.  Headliner can be purchase at fabric stores.  It's usually about $14.99 a yard (http://www.joann.com/joann/catalog/productdetail.jsp?pageName=search&flag=true&PRODID=xprd388109), but I have found it a Hancock Fabrics on sale or clearance fro $4.99 yd.  It's really wide, so again you get a lot out of one yard.

Julie

Are you talking about attaching around the "lip" area or the actual mouth plate to the inside "mouth/tongue" area?
If you are talking about the lip area, you can sew it ahead of time rather than hot glue after, and when I sew a mouthplate I then attach the mouthplate inside with spray adhesive.  The 3M Super 77 kind.
I think this method is shown on the instructions for the  Glorified Sock pattern if you have it.
It's so hard to describe things like this!