Before I started making test heads out of different materials I thought I would probably end up making the final thing out of papier mache. I absolutely HATED working with it in trying to make a puppet head and I definitely won't be using this method.
I started by applying milliput to the lightweigt sculpey core to give the head it's basic shape. I then applied papier mache ontop of this. Because of the scale of the head it was really fiddly to work with and I didn't manage to get any definition on his face. (I did give up really quickly without having got very far, but there is no point persevering if it's not going to work anyway!)