I'm going to apologize up front and warn you that this build will probably take me a very long time.
I work on a chef's schedule so I have very little free time.

That said, what free time I have I am planning to dedicate to this project.

http://img11.deviantart.net/531e/i/2016/168/3/0/brewster_full_size_plans_by_kisady-da6n4eo.jpg

He's gonna be a biggun, but I never do things by halves (10ths, quarters, kicking and screaming hundredths, but not halves).

His idea started out as just a random sketch I did on my lunch break he just kinda grew on me. so here are his current full size plans. If I get acess to a scanner any time soon I'll post the concept sketches.

Looks like it is going to be a fun project.  Have you ever built puppets before or is this your first time? Let us know if you have any questions.

I made a few sock puppets when I was much younger, and my mother bought me a few hand puppets (my most fondly remembered was a small green dragon we used to make reading videos for her students), but this will be my first "from the foam up" build.
I've done some costume work and prop making as a hobby so I have something of a grasp of the basics.
Thanks a lot. The community around here seems pretty friendly and knowledgeable.

When you say big, are you talking full body mascot size?  That guy would look awesome walking around events

He will be right around 2' 6" tall. Not sure I'm ready to tackle a Sweetums build just yet.

That isn't a bad size.  If you incorporate a vent hole (back of neck) he still would look great being carried around and interacting with people.  Sweetums style is difficult, I think I have the costume aspect down.  Just haven't learned how to incorporate the puppetry side of things to them yet. 

Hey there Guys! My last day off I got around to patterning the head.
I had some difficulty finding any kind of tutorial for specifically this task so I borrowed  some technique from a video I found on Patterning foam armor, and smashed it together with some skills I already had.
Edit:
Dead link due to idiocy. Will re host when off work.

Looks to be a dead link.

Dang. Forgot that my facebook settings were "friends only" I'll re host when I get off work. Sorry.

OKay! Sorry about the earlier kerfuffel.
Hopefully this will work for you.
http://img02.deviantart.net/ac16/i/2016/173/f/c/20160620_083403_by_kisady-da77tcv.jpg
http://img00.deviantart.net/7f1e/i/2016/173/6/c/20160620_084708_by_kisady-da77u5m.jpg
http://img06.deviantart.net/ce3d/i/2016/173/3/5/20160620_184417_by_kisady-da77uds.jpg
http://img04.deviantart.net/4a74/i/2016/173/9/0/20160620_191203_by_kisady-da77ujr.jpg
http://img04.deviantart.net/17c1/i/2016/173/b/d/20160620_193449_by_kisady-da77uq3.jpg
http://img02.deviantart.net/8d25/i/2016/173/8/e/20160620_200859_by_kisady-da77uu9.jpg