I enlarged a Rotondo pattern for a mascot head and am now looking at ventilation.  It will be a patched teddy bear, so I will be taking advantage of using mesh patches on the top of the head where I will cut holes into the foam.  I am also looking at doing a hollow "snout" where I can also put in a mesh patch.  I know I want to do some sort of exhaust fan, so am looking for suggestions.  Looking online, I see some using computer type fans and also what I think are termed squirrel fans.  Does anyone have any experience with these?  

I think I am wearing the head sideways, but that is how it works best.  Glued a baseball helmet in, and have put the snout and its vent hole in.  Might have went a bit big on the nose area, but it will be wrapped in polyfilled fleece to smooth it out and give it more of a stuffed animal look.  The head will be wrapped in batting to do the same.  I think I am just gonna do mesh under the nose and have the fan at the top of the head.  Still debating on what to use for eyes.  This character wont really have a mouth, going with the embroidered line smile on the nose.  He will be shy and will have a puppet to do the talking for him, the perfect ventriloquist :D  

Pulled a fan from an old computer, and cut a place for it in the top of the head.  Will attach it with a lot of velcro, so it will be removable if necessary.  After some research, I think the "squirrel" fans would be worse, blowing hot air onto my bodysuit.  Now to order a battery pack and figure out how to wire the two items to a switch.  I just cut out the pattern for the head and pinned it on to see how its looking.  Kind of amazing how a side shot looks perfect:



But front on looks...off.  1) Looks a lot different in person then what you see on a picture 2) Hoping the snout rounds out after sewing and tugging.




Eyes will be bigger and he needs his ears.  He will also have a couple of patches on the yellow.  Almost time to start work on his puppet.  Going to use a pinhead pattern from Project Puppet, though I have to enlarge it enough to fit a fur covered hand in. 

I am sure once you sew it together it'll smooth out. Looking good!

Slowly coming together.  The patches will have visible black stitching and still deciding on nose/smile color.



I do feel like something is off with the eyes.  Any suggestions?  Also going to attempt using burlap patches in snout and over the fan for air flow.  

Looking good!  For the eyes it might help if you put white highlight on them  or even more detail behind or above.  Google either "cartoon eyes" or "cartoon bear eyes" and look at the image results.  I think that should give you some ideas and inspiration.

Thanks Shawn!  Kind of amazing what a little white can do for eyes.  Now to figure out what to use on sunglass lenses :D

Short video test with ears and patches in place.  Still need to do nose/smile and the eyes.  As well as the vent patches.  Any tips on sewing burlap?

Working on the bear's first, possibly main, puppet.  Saw a fuzzy ball puppet I liked and decided to attempt something similiar.  Opened up The Foam Book, and well...came out with this general weird idea :D





He will have big eyes and small arms and legs.  Arms attached to the top part, legs to the bottom.  Thinking he will be wearing gloves and converse type shoes.