WOE and/or muppetperson - was wondering if you could provide some insight for me. Maybe I'm just being single minded because he's my favourite character, but can you help me understand what exactly the huge challenge Fozzie apparently poses? As far as I can tell he's a perfect option for a factory... the amount of fur required would make it appropriate for a large order to be custom-dyed, the fact he has fur means they could get away with no Henson stitch and instead rely on the pile to hide the seams...he would be, in essence, a big teddy bear (with an armature, and that's not all that uncommon). The only potential issue I can see if getting the exact head shape, but there I would suggest instead of foam a vacuum-formed plastic "skull" to give the right shape (people rig these things up in their garage to make Star Wars armour over clay forms...it's not especially expensive) and you're pretty much set. With a rigid skull form underneath you'd actually have a tolerance for error as it would be able to stretch the fabric into shape a little if required. Apart from "he's big" I just can't see the problems - as I said, I would have thought that would actually be a plus in terms of making custom-coloured fur viable.