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Generally, I'd recommend permanently sewing the neck in (just be sure to use a non-stretch fabric). Years ago I tried velcro and safety pins and I found that the pins can rip the puppet if you're not careful and the velcro wears out. There are exceptions though, it really depends what you want...

Great work! The control for the mech looks especially impressive.

I work with hard drive cameras that use the AVCHD format, and I like them a lot. The AVCHD format is 1920x1080 and the MPEG 2 compression is supposed to be vastly superior to other formats. I love the format because the quality is great and it's really easy to work with; you just plug in the...

For prop guns, check out IndyMogul, which has a lot of good tutorials on making prop weapons. I like those BSG puppet designs.

Rigid masks, yes. If you want flexible masks (animatronics) then it probably isn't the ideal material to work with.

Congrats, doing a feature-length film is a huge accomplishment. When do you expect to be finished editing it?

Contact cement will melt Styrofoam and certain other kinds of closed-cell (non-porous) foam. For gluing fleece to foam you might want to try using a spray glue like Super77. It's a really good idea to test any adhesive on a sample of the material you want to glue before gluing it so you know for...

What kind of foam are you using? You can use contact cement on open cell foam (the squishy, sponge-like kind), but it does melt some types of closed cell (hard) foam, like Styrofoam.

You can make round foam noses either by using nerf balls, or by carving foam and then (very carefully) sanding it using a belt sander.

This is so very true. I think profanity is often mistaken for humour. It seems to be a crutch that people tend to rely on.

The Tough Pigs have done this successfully...and there were informal MC dinners when the Muppets were auditioning replacement puppeteers (now let us never speak of that dark time again!). I think the challenge is location.

Is the messed-up logic behind that that it's OK to poison kids...as long as someone else got poisoned first? :p

Wired has a nice photo spread with images and an explanation of how they build various things for the movie in its latest issue. I don't think they've put it online yet, but they probably will soon.

How did the sale go?

The guy is being sued by Disney because of replicas (as Rickly already explained). That should tell you what you need to know.

As currently written (Congress has not yet passed any revisions to my knowledge) I thought that the law was retroactive and had effect on old toys. Usually that's the way these sorts of product safety laws are written. I've read a lot on forums about people looking for loopholes. The problem...

Uh oh. :rolleyes:

I don't believe you can produce crappy anything...

It's not nearly as big as Comic-Con, but yeah, it is the puppetry equivalent. If you can afford to go, you won't regret it.

Most of the puppets I build now are Bunraku-style and have rods at the elbow (permanent), but I do like removable rods. The method I usually use is this one.