Skesis as in the Dark Crystal? That would be ideal. Thank you both. I have never heard of this product so will definitely need to do some research - it sounds amazing and a great alternative for me, particularly if it means I don't have to build him again! Wow, I really have SO much to learn about puppet building. Thanks again for your help.

Deb, I haven't seen the dead terrorist sketch. I try not to watch too many puppet videos believe it or not as I find their brilliance kind of zap my confidence.  I'm working on a script though that will involve all my puppets and there are more to be made to see it come to fruition. I am in no way a performer (except at home!) so am incredibly daunted by this but also excited to actually have something to work towards.

Thanks again

A walking foot on the sewing machine can help with spandex and Lycra. Also you want to use a slight zigzag stitch or else the seam tends to pop on you when the fabric is stretched. 

The needle is important also. I think it is a ball point you want but for some reason at the moment I am not sure of that... maybe someone can confirm that.

Here's Dr. Megan with a video:

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https://youtu.be/2McSZdOazCE

I would have mentioned an overlocker as a potential solution for sewing stretch fabrics but it seemed irrelevant with the possibility of liquid latex as a covering option. However, if you have a friend who owns one it would be a very useful thing.

Like him! He would make a great blacklight  puppet.  White antron glows and resists dirt and such much better than anti pill fless.  That is what we use if a puppet requires white even if it's not a blacklight puppet.

They do make stretch vinyl, 2 and 4 way stretch.  Most I've seen is shiny, but it might come in matte.

Julie

Lizzie,Shawn is right-if you are sewing Lycra you need a ball-point needle. The size is normally 70 and they are usually tipped with a red or blue colour so that you know they are ball-point and not ordinary needles. All the best with practising performance-at home in front of the mirror is a great way to do it. (or with family members if you're not put off!).

We used to spray scotchgard on puppets to keep them clean, do they even make that anymore?

Yes, snail, Scotch Gard is still made-I use it to treat the felt fabric.

Lizzie-if you decide to go down the liquid latex line, there is a company in South Australia who have really good prices. I haven't ordered from them as yet-I still have latex from a previous supplier. Their website address is: www.amcsupplies.com.au.
The stuff is listed under the dangerous goods act and the smell is really strong, so it needs to be applied in a well-ventilated area-I do mine in a sheltered area outside. Several thinner coats are preferable to 2 thicker coats, which will take longer to dry (especially at this time of the year)and can end up just looking lumpy. You need to allow plenty of drying time between coats. Since your puppet is so large, you may need to order the latex in a 5 litre container or larger. The company I mentioned above has bulk amounts up to 20 litres.If you want to see what the latex looks like when finished, go to our website and look under the Lookalikes heading in the menu bar. Scroll down to the bottom of the page and you will see a George W. Bush lookalike that we built for a guy in New York who had a cable t.v. program. Good luck!

First, what a great looking puppet. next, wow! I finally learn how to sew that lycra/spandex stretchy stuff. I wish I had known it a few years ago... but better late than never! I shall no longer be afraid!

Wow, thanks so much everyone! Really overwhelmed by your feedback and keen to try some of your methods. I do have a walking foot for my machine but will need to purchase some ball point needles. I have an overlocker but have never thought to use it for anything but dressmaking, stupid really, so will give it a go! I  intend to purchase some of the liquid latex. The only downside I really see is my own impatience. I like to start and finish a project in a weekend as I hate things being half done. I'm really not sure how I'll go waiting for multiple coats to dry but I guess it'll do me good to learn some patience!

The Scotch Gard is a fabulous idea. Can't believe I haven't though of that - so simple!

Thanks everyone! No doubt you'll hear my huzzahs of elation or groans of frustration soon (really not looking forward to the lycra mission!)