I've started to carve a head out of balsa wood, it was a material suggested to me that might work well in a previous feedback session.

Here's how I got on:
I really liked working with the wood, the only problem I came across which I didn't realise when I had started was that I was carving the wrong way into the wood. I had positioned the grain at the front where his face is so would do this again with it on top so as not so affect the carving. I'm not sure if this will be the material I will use yet, I still want to test other methods. The two main concerns I have for the balsa wood are whether the detail of the face will show up well under camera and what I will do about the eyes. I shall test these both!
 
I have started making protypes following the last scale drawings that I posted up here. I have decided to make two, each out of different thickness wire so I can see which better suits my puppet.

Here are some images of the making of the armatures:
Above: twisting the wire

Left: applying milliput to the chest and pelvis
Left: measuring out the ploymorph bones

Above: measuring out the K&S in two different sizes
Left: the wire hand armature

Above: applying milliput to the palms
Attaching the bones to the wire         
Lightweight head core and eyebrow armature
Above: making the tie-downs in the feet

Right: the finished product
Attaching K&S to the wrists
Attaching wrist bones which contain slot for hands to attach

Left armature is made out of 1.2 mm wire, the right is 0.9mm.
 
This is the product of my day today. I've been working on a new scale drawing of the librarian puppet along with a new design for the armature. Following my previous designs with the abnormally positioned shoulder joints and finding these didn't really work, I have re-worked my design back into a more 'normal' human body shape. I have also re-worked his outfit so that the coat tails are on the back as the main shot of his whole body is from behind him and will look better on screen.
I'm still yet deciding on the design for his head armature, it depends on what materials I use to create it. If I carve his head out of balsa wood then he wont need a lightweigh core, the K and S will slot straight into this, however if it is made out of paper mache or mod roc then it will need a lightweight core for the K and S to sit in.
 
It was suggested to me in a feedback session on my work in progress that I look at making the puppets head out of something like balsa wood or paper mache which will give it a more tactile and angular feel (and will also be extremely lightwight!). I am going to try those particular methods but this got me thinking about other lightweight materials that may work well.
 I have never used mod roc before but have seen it used in a previous production that I worked on so thought I'd give it a go. Seeming as I had made a sculpt I thought I would apply the mod roc straight onto this (cling film wrapped around the sculpt to protect it), let it set and then cut it open to take the sculpt out then reseal.
Although not great at intricate detail this was an extremely quick process (if you already have a sculpt made) and is extremely lightweight. I am going to build on top of this to make it look like a character so this might solve the problem of lack of detail to begin with so there will be a post again soon of how that goes...