PUPPET HEAD ASSEMBLY Resumes

 When last we left our puppet assembly the eye and mouth animations had been attached and tested. The wire frameworks for each head have now been finished and as shown above the lower jaws have been built up from cardstock and masking tape, and attached to the mouth blocks. A "mask" of cardstock strengthened with masking tape has been fitted individually around the eyes and hot melt glued in place to the wire frames. The black painted "eyeliner" will only show a thin rim of black around each eye once the felt skin has been attached.

They still look pretty spooky this way, but you can start to perceive the individual personalities:
from left, MARGUERITTE with flashing blue eyes, Behind her is GOLO the timid giant, then at right REYNARDO the fox, and in front green eyed CARROT TOP.

MARGUERITTE and CARROT TOP have eye animations which open and close like a doll's. GOLO and REYNARDO'S eye animations shift side to side, and their eyelids are fixed in position on the face mask ( eyelids made from sanded and trimed plastic christmas ball ornaments to fit over the moving eyes ).

The next step involves building up the rest of the face. In the past I would use ordinary 1/4" packing foam rubber for this, but I now prefer 5mm thick Craft Foam sheeting as shown above. This material comes in several colors and is just as plyable, but with a smoother more durable surface than the old foam.

I use contact cement to join foam to foam and foam to other surfaces. You paint the cement liberally on each seam edge or surface to be adhered and let both dry for 15 to 20 minutes. When tacky, the pieces can be joined quickly and permanently together with a bond that only strengthens as it ages. Above is a good pictorial example of this process in action. The forehead section has been attached just behind the top "mask" and atop a shaper strip of corrugated cardboard which defines the edge of each head. Side sections will be fitted and glued next, followed by a nose/lip piece which will be positioned under the eyes and shaped to fit the individual character's face ( REYNARDO'S snout has been attached already ). The backs of each head will be molded entirely of this foam sheeting and hinged at the top with velcro fasteners on either side.

I'm very excited about the possibilities of this new foam sheeting. It is far superior to older foam and much more durable without adding weight to the puppet.

[ A note of caution concerning Contact Cement:
The fumes from this product are Extremely Volatile! I have made the mistake of attempting to use this indoors. Even with amazing ventilation, you can easily be overcome by the fumes. The added combustibility also makes indoor use dangerous. I generally set up a table outdoors on the patio or deck and do my cutting and painting of the cement out there. Dried pieces can be safely brought into the studio to be joined and attached as the solvent has mostly evaporated by the time they are tacky. ]

Next the final felt skin will be fitted and glued to each head....