Gonzo
Robin,
Sadly, most Muppet fans probably wouldn't be able to afford an exact replica of any Muppet character. When I mean exact, I'm talkin about like when you buy one of those Starwars X-Wings or Tie Fighters that were put out by Icon Replicas. If we were to take Gonzo for example. His price range would most likely fall between 4 to 5,000 dollars. I know this for a fact, this is what most Muppet principal characters cost to build at the shop. Lets start off with his head, its basically carved out of a block of scott foam. First problem you'll encounter is that if you're a novice puppet builder you're not goin' to be able to find a chunk of scott foam any smaller than a mattress size. This is how most puppet shops have to buy it. The same is to be said about the scott foam sheet you would need to pattern his body from.
Fur is another problem, best of luck to anyone who is going to try and find a fur that matches him exactly. Gonzo is not made from the same type of fur that most Muppet monsters are made from like Elmo. His fur is a great deal more complicated and if you were lucky enough to find it you would have to buy the entire bolt of fabric. Gonzo's fur is a mixture of blues that are a bit darker towards the backing of the fur. Also it has a slight curl to it and also a softness to the touch, and lets not forget that it also has a weird shine to it. It is all these little things that make him so special to duplicate. Infact, most times when he is rebuilt the puppet builder will rough out several heads to see which carved head is closer to the last primo version of him.
Although the pattern to his body is not that complicated his head is an entirely different story. The odds of screwing up the sculpt are there to the end. Not to mention that once you are finished with the outside carving, you need to begin to hollow him out from the inside for your hand. Next the base color of the foam needs to be dyed a bit yellow to match what the last primo looked like after aging a bit because the scott tends to go yellow, after this he gets sprayed either by pre-valve or airbrushed for his bluish color for his nose. It may be a lot easier if you were to build him yourself. The person I know could do it, but it's going to cost somewhere in the price range mentioned above.
I'm tryin' to think of what else I can mention to help you a bit. On the plus side Gonzo's hands are probably the easiest Muppet hands to make. It's basically two cut outs sewn together. His hands do not require what Elmo or even Grover's hands need to work. Same goes for his arms, they're just fur nothin' on the inside like Elmo. His arms are just like Grovers. They both just flop around. Also, Gonzo is much closer to Kermit in size, so he is one of the smaller versions of Muppets. Just picture your hand as if it were in the head of the puppet and add his nose. That's pretty close to his size. There's not much room in there for anything else. Unfortunetly his eyes are a little more complicated to explain at the moment so I'll leave that for some other day. What's left... Well, like I said he is small. So he doesn't require a lot of materials if you are one of the lucky ones who have this stuff lyin' aroud your puppet shop. If not you're goin' to have a bunch of extra puppet supplies for some time. His hair is pretty easy just pluck some ostrich feathers in there that match his color. Color is basically a brownish-grey. Do not hot glue them in because this will melt his fur. Use some typ of fabric tacin' glue. I'm just starting to throw things in now. His mouth is a dyed redish brown scott foam probably 3/8 thick and it also has a very fine knit black fabric sewn on the inside that shows through were his upper mouth has those three slits. His tongue is not felt, but also a dyed piece of leather called ultra-suede. And his pupils also are not felt but that black shelfing paper you use in you cabinets. These are punched out, not cut. I think that's enough to at least get you going in the right direction if you want to build it yourself. Now if you happen to be a very wealthy Muppet fan and still want him built. It can be done....lol. Happy puppet buiding to all.