So far i have made puppets two ways, with a pattern I made after seeing it on the computer, I think it is the blue boy pattern, and by sewing a back and front and cutting a slit to insert the mouth board. I have added ears, horns, etc, but how do I get a square mouth or a gonzo type nose? Are there some patterns somewhere or can someone show me a drawing even? I am about ready to make a model and make my own pattern at this point. I am still not using foam, so I am just looking for a pattern for material.

I have found a few patterns on here and elsewhere that I am trying to compile on facebook page "Making Puppets".  I think the link is in my signature.  Maybe they'll help? 

There is also the Foam Book by Drew Allison and Donald Devet of Grey Seal Puppets. http://www.greysealpuppets.com/FoamB.html It details the three piece head method of making a puppet. With this method you can do just about any shape you want. It's a really good basics book.