Puppet torso
Every puppet seems to require a slightly different approach to making the body. But this is how I usually make the larger puppets.
Sculpting
For the larger puppets I start by cutting out the body shapes in MDF, using a scroll saw. Where possible I remove wood from the inside of the shape to reduce the weight of the puppet. I use these profiles as templates to sculpt the body parts. I prefer to sculpt the body from a soft foam rubber as this is the most sympathetic when it comes to using the puppets. There is no sound when the puppet knocks against things, it is lightweight and it has some give in it, like skin. However there are often occasions when it is better to use a more rigid material, like syrofoam. This is usually when the limb will be seen, and not covered by clothing. For example the bottom of legs and the lower part of the arm. Both materials will need some sort of covering to protect them. I cover soft foam rubber in stockingette, which is glued to the surface of the foam with copydex. Styrofoam is more problematic. I usually cover it with fibreglass and resin, which can then be sanded to create a smooth finish. However, you cannot apply resin directly to styrofoam, firstly you must apply a barrier layer of tin foil, which prevents the resin from destroying the styrofoam.
Joints and assembly
There can be a lot of pressure put on joints and fixings.
The arms and legs have strips of aluminium for extra strength. The aluminium run the
length of the limb, and is bolted to the MDF profile.
For elbow and knee joints, where the movement is like that of a simple hinge,
I drill a small hole in the aluminium and connect the limbs with a 3mm diameter bolt.
For looser joints such as the shoulders, hips and wrists, I use webbing,
which allows the limb to twist and move in any direction.
The two or three sections of upper body are also joined with webbing, either one or
two pieces running down through the centre of the puppet.
At the top of the body there is an aluminium and wood shoulder section. At its centre
is a hole, through which passes the neck of the puppet. Attached to either end of it
are the arms. The underside of this section rests on the handle of the puppets
head mechanism, so it must be quite a strong construction as it will support
the weight of the puppet below it. I attach this shoulder support to the MDF
profile of the body. The back of the body is hollowed out for the puppeteers
hand and the handle which controls the head.