Will be atteding a convention in October and decided on dressing up as a cosplaying puppet.  Purchased the Roly Poly pattern, and increased it by 250%, which allows it to fit over my head.  However, not sure if I am fully satisfied with the way it sits.  Any suggestions on altering the pattern so the mouth is a little more closed?  Plan on using foam.

Poor mockup with a paper version:

Have you thought of some boning to give it some framing? It looks like you're using the Roly fabric pattern, and not the foam skull. The foam skull is much more of a dome, with the addition of the mouth plate, the pattern opens wider.

You could build a foam skull to have as almost a hat. If you want your face in the mouth there you could still do a mouth plate just cut the dotted center (the size of the mouth plate pattern) out of the foam mouth pattern. With some boning it should hold its shape. Search the web for the fraggle costumes, and you should have a similar finished look.

Cool idea, and good luck. Share when you're done please, I can't wait to see the finished results.

That is a good idea, thanks!  I started off thinking that I could use the foam pattern on felt and stitch it together.  It...works, but the results are not great.  Did learn that hot glue is not the way to go if using foam in that manner.  On the mouth plate, I was thinking of using the complete foam pattern, and simply cutting holes for the eyes.  Seems like that wouldn't be any different then any other mask. 

This is definitely a learn as I go process.  I started with the thought that I could build it around my head without a patter.  Yeah....

Is there a specific look or character that you're trying to achieve, or are you trying to apply puppetry to a costume?

I think enlarging the Roly pattern as you've done could work well, but stay with the materials you would use in the smaller scale, form as indicated, and fleece for the pieces in your first pictures.
Since you're wearing it you'll want to keep the weight down.

I've read else where the boning (http://www.onlinefabricstore.net/sewing/boning-corsetry/boning/covered-boning/covered-boning-white-.htm)  is the way to go to keep it light but provide form.  This boning could be sewn in or possibly glued.

I was looking at these things to create a Monster's Inc like full body costume/puppet. I couldn't nail the design of the head(s). I wanted one that I could have one head piece that was like Bear-in-the-big-blue-house controlled by hand, and a second that could sit on/around my own head.

BTW have you used the Roly pattern before on a smaller scale?

The idea was the generic "person" Muppet, something that looked obviously puppet with the rounded head.  Being the first attempt, this is purely costume and will be a fixed face.  However, in the future I hope to include a movable jaw and potentially blinking eyes.  Would love to do something similar to Big Bird.  

*ETA* I have not used it on a smaller scale.  I have used the Glorified Sock Puppet...once.  I know this is a big undertaking, but am enjoying the challenge and the lessons being learned.  They are being learned the hard way, but its still fun.

Don't know that you'll really need boning for the size you are needing. If you are using 1/2 - 1 inch foam you should be ok. I personally would use what is called EVA or close celled foam but not everyone can get it where they are. It is a much denser foam so holds it shape better.  With the scale you are doing you should be able to look out the eyes of the puppet although having screen in the mouth would allow even better range of vision.  Instead of using a solid material for the mouth plate see if you can find some black plastic canvas. You can't always find black but you can paint it if you can't. Found normally around where the yarn is in hobby stores. You might still want to make the lower half of the mouth solid for stability and look but if the upper half and towards the back of the mouth is made of the screen it allows you to look down and out.  Just make sure when you are wearing the head that you don't tilt your head back to look out.  It is common for beginners to do this since the mouth area is often more open then the eyes and easier to see out. The problem is that then your puppet head is always looking at the ceiling.

This is what I wound up with:



Still see through the mouth, though I am playing with it a bit.  Might have stuffed the skull in wrong or did a poor sewing job which prevented it from going in.  Regardless, I think its turning out ok for a first attempt.  Gonna have to go back and cover the seams in the mouth, as I did that off pattern for vision.  Also have some extra fabric bunched up around the nose, trying to utilize it for that purpose. 

Looking pretty good. Yes I think if you add a nose that will take care of the extra bit of fabric in that area.

Some polyfill really helped the nose. 



Still working on the mouth, had to increase the vision and free up room around the mouth and nose.  The hair...I learned a good lesson today, don't try to do it in one piece.  Thinking I should have put it on in 2 pieces following the middle seam.  But, the bumpiness of it almost adds to the illusion of unkempt hair. 

Also will be working on sleeves and gloves. 

I purchased some character heads years back now ... i bought them naked and did all my own details ....I'd love to make one of these myself. you might get some ideas. here is the the link http://s167.photobucket.com/user/valitascrafts/library/puppets%20ive%20made?sort=3&page=1