The Count's nose sticks out just a little, but it doesn't require the shape to change all that much. Not to mention it countours without having to sacrifice shape. Big Bird's beak (logistically) would have to be manufactured facing down ward or sideways to fit the same requirements. It wouldn't look good. I could provide a small sketch to show you what I mean. I'm sure they thought about Big Bird, but couldn't get the logistics together to make it possible. Plus, I think the SS has the highest assortment of any of the other characters they have. Even Disney only has Mickey, Minnie, Pooh and Tigger.