An Insider's Guide to Techniques

Using Patterns

Tracing and cutting out patterns is an important part of building a professional-looking puppet. A mistake can leave you with pieces that don't fit or a puppet that doesn't work. For the best results, label your patterns, and slowly trace and cut out each piece.

Preparing the pattern

Trace the pattern on a piece of paper and cut it out. Use the paper to transfer the pattern to a piece of cardstock. The cardstock has a stronger edge and will last longer. Try to match a straight edge of the pattern with a straight edge in the cardstock. Cut out the cardstock pattern.

You may need to trim tight areas in the pattern multiple times so there's room for a marker or pencil tip to make an accurate mark.

Cutting fur

For cutting out fur using a pattern, lay the pattern on the back of the fabric, not on the fur itself. Trace lightly. Make sure the ink you use doesn't bleed through the fur.

Cut the fur using only the tips of your scissors. Try not to cut the shag of the fur as it will leave marks that are visible on your puppet.

Creating Eyes

I've spent a lifetime searching for the perfect puppet eyes. I started out sewing ice cream spoons to my puppet's face, but that didn't work well.

I've discovered many methods for creating eyes, including this one. Bubble stickers, made primarily for scrapbooking, look like big contact lenses. I created eye color patterns on my computer and stuck bubble circles over the eyes to give them a convex shape.

Basic Eyes

Make a color copy of the eyes from the template below. Enlarge or shrink the eyes as necessary to fit the puppet. Cover the eye with a plastic circle bubble sticker. Use larger stickers for larger eyes, and smaller stickers for smaller ones. The sticker should be slightly larger than the eye.

Cut out the eye and bubble sticker from the paper. Trim around the bubbles carefully using scissors. Place the eye on the surface of the puppet. Use adhesive to secure.

Professor Foaman's travel tips

Be careful when placing the bubble on the paper eyes. Line up the bubble slowly and then push it into place, pressing out any unwanted air bubbles.

Eye template

Working with foam

Foam is an excellent material for puppet making, and it's not hard to work with. This is one of my favorite secret techniques, and until now it was known to only a handful of people. With it, you can smooth and round the foam of a puppet, giving it a professional appearance.

This technique can potentially damage your puppet if done incorrectly. If there's an area that doesn't need to be smoothed because it's covered by hair or clothing, don't smooth it. Take time to practice before you work on a final project. You'll need a variable-speed, preferably at least five speed, Dremel in order to use the slower speeds for this technique. Wear a mask and safety goggles and keep the Dremel away from your face, loose clothing or hair as you work. Make sure there is no one near as you operate the Dremel.

Smoothing foam

Find the center of a small circle of sandpaper. I use a 2¾" (7cm) diameter circle of medium, general purpose sandpaper, preferably 100 grit. Screw the sandpaper onto the screwhead bit of the Dremel. I've found that ⅛" (3mm) stainless steel mandrel bit works well. It comes with two washers that anchor the sandpaper. Hold the foam firmly and use only the lowest setting on the Dremel. Hold the Dremel firmly as well, keeping your finger on the on/off switch as you work. For smoothing flat areas, lightly brush the outside front edge of the sandpaper. Only work on the front edge of the sandpaper, not the sides or back, or you risk the Dremel ripping the foam.

For rounding corners, hold the puppet and the Dremel tightly and use light touches with the Dremel as you slowly move the puppet.

For tight corners, press down the foam around the rough area so the foam you want to sand pops up. Sand carefully, keeping the area around the rough spots pressed down.

Basic Sewing

Verna Finly, a Legendary ventriloquist puppet builder, taught me her method of sewing puppets, which she called the overhand basting stitch. With this method, you lace the edges of two fabric pieces with a needle and strong thread, drawing them together slowly and tightly to create an invisible seam.

There is a secret to fitting the fabric over a puppet. You need to make as few cuts on the fabric as possible and keep your cuts on each side of the puppet symmetical, then smooth it. Glue the back down first, keeping the face fabric tight and smoothing it where the fabric bunches, then pin the edges before sewing. Thanks, Verna!

Preparing the needle

Thread the needle, and then tie the end of the thread in a big, loose knot.

Roll the knot in your fingers and pull it tight to keep the thread from sliding through the fabric.

Sewing Fabric

To sew two pieces of fabric together, push the needle through one piece of fabric near the seam, then back out. Move to the other piece of fabric and repeat. Make only five or six of these alternating, loose stitches that will look like the laces of a shoe. Tuck the edges of the fabric in and pull the stitches taut. Make adjustments to the fabric as needed with the tip of your needle.

Continue making alternating, loose stitches, tucking the fabric in and pulling the stitches taut every five or six stitches. To end a stitch and secure the thread, make several loops and pull them tight. Make one more loop and leave it loose. Bring the needle back through the loop and then pull it tight. This will knot the stitch closed. Trim the excess thread.