I know this is an old thread, but nice job! I know from experience how hard it is to figure out how to make a puppet, and to come up with a pattern. I'm wondering, where did you put the hand hole, and in the end did you like the placement? I've never done legs, because I wasn't sure of where to put the hole.
I was able to correct the problem with the pattern, and I have verified that the pattern in the PDF works. Unfortunately, I did not check the PDF last time, just the images that went into it. I'm sorry for any problem this may have caused. The pattern pieces are now split into page sized junks to keep my program from scaling them. Again, sorry.
A word of warning. The head pattern I posted is wrong. The PDF program I used scaled the images. I'm checking the reformatted pattern, and will let update status when finished. To anyone who downloaded the pattern, I'm really sorry.
When I printed out the pattern this time I also thought it looked small. That is why I wasn't sure which pattern it was, as I had tried a few different sizes. This pattern was labeled with the number I remembered, so I put it together and it is the right one. It ends up being bigger than you'd think, I was surprised.
I tried hot glue at first, and that was a disaster. I also ended up with burnt fingers, and never got any of the seams to stick. Contact cement is great, it is just a bit messy and slow. I've seen people put it in a refillable mustard kind of bottle and just squeeze it on and spread it, but I've never tried it. If you feel impatient, there's always super 77 spray adhesive. It's practically instant, and I use it for prototyping. The only problem is that unfleeced heads left in the sun and heat will come slightly unglued. They won't come completely apart, but you can see the outer part of the seams lifting apart. Fleeced though, it holds together, and I haven't had a problem. People use super 77 for puppets, and mascot costumes, but I still use contact cement for a final draft. I think it's just because I know it will work, and I've only been using super 77 about 7 or 8 months. I still have a puppet that's perfectly in tact, fleeced, and no signs of splitting, but it still makes me nervous.
As for flexibility, this puppet works out very well, contact cement is flexible. Resting, the mouth is open, that way it's easy to open and close. The only warning I have for you, is to be very careful to line up the edges of the mouth board and the corners of the head's mouth. If they don't line up just right, the mouth will tear a bit until it reaches the mouth board's hing area. The tear will stop and then function normally once it hits that spot, but you're mouth will be slightly crooked, which won't be very noticeable until the mouth is closed, and the dimples are different.
Remember when gluing the mouth in, not to push the seams together until you are absolutely certain, because once you start to press them together, there's really no coming back. I've ripped a number of puppets when trying to reposition the mouth after I started to finalize the seams. The mouth will stick as you position it, but you will still be able to reposition it until you pinch it together. The mouth board is tight, and the foam of the head actually has to stretch in order to accommodate it. This is intentional, but is a little difficult to work with.
I've updated the pattern link, and altered the mouthboard directions. I'm glad I decided to do a mockup on the original pattern, as I saw that the mouthboard I included in the original pattern was wrong. It was about a 1/4" too small all around. I'm sorry to the person who sent me a message saying they did not line up. My illustrator file had a different mouthboard than the one I had included in the pdf, so I did not understand what you were referring to.
Hey Ashley8bit. I've tried modding this pattern a few times. And cannot remember which pattern is the good one. I'm pretty sure I know which file it is, but let me knock one out real quick, and I'll get back to you later today. Sorry it's taken so long, I just saw the message in my inbox.
This is awesome. I really like the style. He reminds me of the old marionettes. I'm curios as to what he's made out of. I like the texture of the face, but I can't tell if it's the material or your paint job that gives it that look. I was also wondering how big he is?