I'm going to try and do this puppet project for my first attempt:

http://www.expertvillage.com/video/1287_building-a-moving-mouth-puppet.htm

The thing is, I'd like the head to be larger, and a different shape. I'd also like to set up the arms so I fit my own hands inside to manipulate them, cookie monster-style. I'd be okay with only having one hand that can be worked, and the other can hang loose. Here's a rough sketch I did of the head:

http://haroldjennett.files.wordpress.com/2012/02/firstheaddesignv2.jpg

I assume I'd need something to fill the head out, like a larger piece of foam perhaps? Would it be possible to just use plain old stuffed animal stuffing to fill the head, rather than the folded foam technique Paul uses? I'm just trying to think of some other options.

Also, what would you guys recommend for the sideburns, beard, and hair? I'd like them to be orange, and I'd like the hair to have a combed down look. Also, what's the best way to measure out the beard/sideburns to make sure they fit right?

I'm imagining for the glasses I could just get some cheap dollar store readin glasses and pop the glass out.

Thanks for any feedback!

To me your design looks like two cones set bottom to bottom with the bottom one being smaller.  Get some foam or even just paper and try to make two cone shapes and go from there.  To make pattens for hair and such use either paper or cheap cloth that you lay on the face and the do a quick sketch of the face. Cut that out and see how it looks and fits. Fake fur makes great hair and comes in cool bright puppet colors.

Looking good so far!

The character is great! I have sent you a PM - I may have something that will help.

To me your design looks like two cones set bottom to bottom with the bottom one being smaller.  Get some foam or even just paper and try to make two cone shapes and go from there.  To make pattens for hair and such use either paper or cheap cloth that you lay on the face and the do a quick sketch of the face. Cut that out and see how it looks and fits. Fake fur makes great hair and comes in cool bright puppet colors.

So it's good practice to try making the head with paper, and if I like it I can do the same with foam, and then cover that with fleece? Are we talking the 1/2 flat foam, or an actual block of harder foam?

You can buy at a dollar store the inexpensive foam bed toppers(mattress)........... I keep those on hand to do mock up versions of puppets. You can use a old t-shirt instead of fleece to cover that. You can at this point make a pattern. take pictures of your progress we would love to follow along.

You can buy at a dollar store the inexpensive foam bed toppers(mattress)........... I keep those on hand to do mock up versions of puppets. You can use a old t-shirt instead of fleece to cover that. You can at this point can make a pattern. take pictures of your progress we would love to follow along.

OK, so basically I shape the head with foam, glue it all together with hot glue, or contact cement, put in the mouth plate (made of cardboard and felt) then cover everything with fabric, and sew it all together? I like the idea of using cheap supplies to start out with. Think I might stop by the dollar store and look for some foam

I found some cool stuff on the dollar tree site. Could I use any of this for my puppet?

http://www.dollartree.com/floral-decor/floral-arranging/Green-Foam-Pot-Inserts/202c204c204p62570/index.pro?method=search

http://www.dollartree.com/arts-crafts/arts-crafts-supplies/Gentle-Grip-Green-Foam-Block/209c304c304p294154/index.pro?method=search

http://www.dollartree.com/teachers-supplies/Arts-Crafts-Projects/8-ct-Bags-of-Foam-Craft-Balls/208c447c447p294281/index.pro?method=search

The first link is floral Styrofoam it could be used to carve a nose. The second link however is floral oasis and could not be used. The third link is Styrofoam balls which you could use to make eyes or noses. Dollar Tree and all dollar stores are great places to find supplies.

Billy is right on his details of the foam you found.  Styro foam can be used to make noses and such but would not be used to make the entire head of a puppet like you want.  Poly foam is normally used to make the head. Now we are only talking about a traditional hand in mouth (Muppet) puppet. Except for the second link you posted I use those types of foam quite often in making heads and body parts for my marionettes or rod puppets.

A quick note about the second link you posted.  That product is also called Oasis foam sometimes and used by florist to arrange flowers. While it could be used in some types of puppets to carve parts I would not suggest it.  It is very messy.

So it's good practice to try making the head with paper, and if I like it I can do the same with foam, and then cover that with fleece? Are we talking the 1/2 flat foam, or an actual block of harder foam?

Yep that is often what I try to do and yes I am talking about the 1/2 inch flat poly foam. Now paper is not going to act exactly like foam when you play with it but it can give you a starting point.  I try to see the basic shapes in what I want to make and start from there. That is why I mentioned triangles or cones. BTW I really love the shape of the head you are wanting to go for.

There is a pattern out there that is close to the shape you are going for and it may be worth it for you to buy it and look it over. http://www.projectpuppet.com/servlet/-strse-10/The-Punto-Puppet-Pattern/Detail  They also have a pattern for the fabric that goes over the foam. http://www.projectpuppet.com/servlet/-strse-11/The-Punto-Fleece-Head/Detail  They have a cheaper version that is about the right shape also. http://www.projectpuppet.com/servlet/-strse-6/The-Pinhead-Puppet-Pattern/Detail

You don't have to start with a pattern but sometimes for the beginner it is easier.   If nothing else it allows you to see how one dimensional flat patterns translate into three dimensions. I make my own patterns but even I struggle sometimes. What I think is going to work is not always the reality. That is why I always look for cheaper materials I can work with to test things out.