Plasticine sculpt of the head.

5 layers of Papier Mache over the sculpt using newspaper and pva.

I made a simple open and close mouth mech using a string and gravity. Painted wooden balls for the eyes, and lay down a base layer of paint.

I layered the paints to create a skin-like look, he needed to look good both on stage and up-close on film. I used modge-podge to seal everything.

I made the body from blue foam, i drew a scale-drawing to help keep all the parts in the same scale.

The arms and legs were also foam, they have fabric joints at the elbows and knees. I layered on newspaper and pva to help give it more structure and to create a paintable surface.

The arms and legs attatched to the body with ball and elastic joints through pvc pipe. the mid section of the body is shaped to give more bending motion. a peice of canvas runs through the middle of the body to allow this.

The hands were made using Sculpey over a tinfoil and wire armature, and painted with acrylic.

I made a masking tape pattern of the puppets head to use for cutting out the hair.

For the hair, I used faux fur I found in the charity shop. It was very fluffy and ginger so i painted into with brown to try and make it look more natural and textured

I used uhu glue to attatch the hair to the head. The handle on the back is PVC pipe with a trigger for the mouth mech.

I drafted a simple pattern for the jumpsuit, I cut it out of fabric from a pair of second hand trousers.

I sewed the top and bottom separately then joined them together. I started adding the details that are on the original jumpsuit.

I used velcro on the back so i can take the clothes on and off if i need in the future.

I recreated all the patches on the original jumpsuit using scrap fabrics and acrylics and hand sewed them on

More details, I copied this patch from the jumpsuit Laurie Cousins had made, and painted it with Acrylics.

I made the mini shoes by drawing out a 3 piece pattern and cut out of scrap leather and a plasterzote sole. I glued it together, and painted the colour on with acrylics.

The finished shoes. I applied a layer of modge podge to seal the paint on and give them some shine.

Finsihed Puppet held by Hector himself

The finished puppet.