Zoot Puppet Help

[TwoHeadedLlama]

Hi all. So I've decided to try making a Zoot replica using the Pinhead puppet pattern from Project Puppet. Trouble is, I know Zoot's head is probably carved into it's specific shape, while the skull for the pinhead is made of of individual pieces put together. Also, it's designed to have a large mouth. I was thinking of putting the foam head together with the pieces reserved for the mouth opening glued shut, then try to carve into it. I don't even know if this is possible, since I've never used this pattern before, but I'd rather not have to carve a foam block. Thoughts?

 

[Muppetlab]

The pinhead soesnt have a mouth openning on the foam skull. It is just the top of the head and the bottom jaw is seperate.
You could try making two pinhead heads and gluing them together to form an egg shape. This will give you a good oval base to work from.. Or maybe the roly glued to the pinhead. The whole mouth on zoot can then be made by cutting it out in the right place.

 

[TwoHeadedLlama]

Alright. Any idea on how to make a mouth plate for the mouth?