Hey Muppetlab, sounds like a good plan. I'm hoping my next (final) version will be made from Antron fleece. I'm waiting for my supplier to get some more white fleece in stock then I'll start experimenting with the colors. I was quite happy with my last attempt, and in pics quite closely resembles the older henson looking puppet which is what I was aiming for, but there are definite tweaks I want to make to get him more accurate in the face, eyes, and mouth expressions. I haven't yet found the right mouthplate combination for kermit, they are either too flexible and don't hold the shape properly, or not flexible enough so you can't do his funny expressions.
would love to hear more about how you put the head together and how flexible your kermit is for expressions.
Greg