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A Few Questions...

SesameKermie

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You would cut a piece of foam shaped approximately like this:



Then, fold the foam in half and glue the seam at the front of the beak (the pointy part.) The rounded sides attach to the puppet's cheeks. Add a mouthplate and a bottom jaw, and you should be set. Gonzo's nose is airbrushed or perhaps flocked, if I'm not mistaken.

Hope I helped,

Jason
 

Buck-Beaver

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I would be tempted to carve it. Unless you're really careful with the patterning and gluing there may be a very obvious/visible seam in the foam or it may look a little flat. It can be done of course, but you can get a much smoother by carving the foam.

John Kennedy describes a good method for carving heads in his book Puppet Planet.
 
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