I've done ok so far using polar fleece.  I've got 1 puppet nearly done, and another about 40% through. (Pictures to come when I have some spare time.)  I was mostly just having issues with figuring out how to add more depth to the faces.  Sometimes a basic head with a few features glued on works just fine.  Some characters need more... well... character!

Yes, Shawn is correct. I cover the nose, hot glue it down in the center then stitch around it.

Look forward to seeing you puppet.

Let me know if I can help.

Julie

My poor brain is finally wrapped around the whole process.  I was still thinking of the steps involved in making the Project Puppet ones.  Basically making the whole pattern and slipping that over the foam.  this is obviously a more time consuming way of doing things, but the quality more than makes up for the extra time involved.

Thanks again for all the help!@

Thanks for the tips Julie!  That will help a lot moving forward.  Always great to see it being done.