This is my 3rd attempt at one of these.  The first one was VERY basic.  The second was more complex.  the head came out great, but the body was a disaster.  Instead of restarting that one's body, I am starting a new monster entirely.

Start with a Hunters face mask ($5 from Walmart). Very thin, made to whisk water away and NOT for warmth. I sewed on 1" elastic to hopefully allow mouth to move with mine.



I then crafted the foam for the head shape.



the foam on the lower jaw is only attached to the elastic around my jaw and not to the other foam. Hopefully this will allow the jaw to move.



The hair is a curly yarn that frays something aweful. but for my purpose, works well. I wrapped it around a piece of cardboard to the length I wanted, and the wife sewed down the middle of the strips making it a strip of hair. Glued down with spray glue.



Inside the lower jaw, I encircled the lower lip with a sturdy wire, then ran it down to form around my chin. Hopefully this will aid the mouth movement.



I couldn't find the plastic domes I wanted so I used 'smooth foam' balls for the eyes. Painted them, added a sticker for the iris and covered them with 'envirotech' sealer to give the glassy shine.



After assembling the head, adding the eyes, mouth, and latex there is LOTS I am not happy with!! Eye color for one. Also, I don't like the nose at all. This will be changed!!! The jaw movement isn't very good. Looks more like a mumble than movement. The method I used was shown on heads that were much smaller and much more form fitting than this big guy. Not sure what to do here. I can tie one arm up with the prop (next pic) and operate it with the arm that was going to operate that. hmmm



Oh, made him a club too.  PVC core covered in foam, then duck tape, then latex.



UPDATE - I cut away the nostrils and finished the nose. I think this alone makes the eyes look much better. Though they still need work. Maybe building up the cheeks below them. Hmmm...? also, still needs work done to the top lip, but I added the plastic canvas there to see out from.

http://puppetsandstuff.com/2008gallery/main.php?g2_view=core.DownloadItem&g2_itemId=26744&g2_serialNumber=2

Still working...

I love the yarn you used for his hair.  Looks great.

Very close on the head.


Made the nose a more normal nose without the nostrils that I had originally done to see out of. Moved the view spot to just below the nose. Built up the cheeks and changed the fur to something fluffier. And added the teeth I cast, I haven't tried it back on yet to see if I can see out of it though...

I didn't really do anything to him from Friday, just tried it on. Might need a small fan by my mouth to get air, but otherwise, it all seems to fit and work (minus the articulated mouth that I haven't messed with since before).

I bought more yarn to fill in places. Found a horrid sweater thing I made years ago that looks great with him I think. Needs hands yet. I bought some feet I am going to cheat and use. Otherwise, pretty close on him I think!

Really like how he looks Arthur! The sweater really works well.

Love it!

This is really cool. The sweater fits as if you had designed it for the creation. Congrats on the fine job.

Agreed. Nicely done.

Congratulations! Great result!.

He's done!!  Ok, I still need to sit down and figure out how to make the mouth move better, but that won't change the pictures!