I did an animation test for the moving eyebrows that I was planning on using on the puppets head. If anything I thought it made him look quite comedic which is not what I want in the slightest so I am going to scrap this idea. I will probably still give him eyebrows on the final head, just not ones that move!
 
I made up some hand armatures with wire and milliput and then skinned them with fine sporting injury foam dipped into latex. I didn't dip them in latex, but left the texture of the foam exposed as I didn't want a shiney quality to them and then added bits of ripped up book pages alike to the head.
If I had the time I would have made the hands out of balsa wood to be inkeeping with the head, however this would require lots of replacement hands as I need them to move, so this is a much quicker alternative and will hopefully not look too alien to each other under camera.
For the hands that you can see above, I used the lighter colour foam (left image), however when I make them for the final puppet I will be using the darker foam as seen in the right image as it matches the colour of the wood better.
I also skinned the other prototypes arms with 80 dernier tights material, which worked better than the woolly material that I had tried previously, as well as the latex for the texture of clothes. However I will be using foam and latex to skin the puppets neck as the skin of the hands will then match this.
 
I tested the two head that worked well under camera and lighting to see how they looked on screen.

Balsa Wood:
Sculpey, foam and latex:
I thought they both worked well on screen. I do slightly prefer the balsa wood for a few reasons, the main one being that it is a really light material and doesn't affect the movement of the body armature. It is also really nice to work with and the definition of the face showed up a lot better than I thought it would. The sculpey, foam and latex head does look really visually nice, however it is really quite heavy and had an impact on the body armature. It was also shiney in places because of the latex and I want to try and avoid this.

What I want to try next is adding book pages to the balsa wood, like I did to the foam and see if this adds the nice textural quality that the foam head has.
 
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!)
 
After my tutorial, it was suggested that I try adding very fine sporting injury foam dipped in latex and applied with spray mount ontop of a sculpey head. Once layered it can look like paper.

Firstly I wound some wadding around the eyebrow armature. I then sprayed a light layer of spray mount over the head and applied the foam with almost dried latex onto this. I used a coctail stick to tease it into the ridges on the face.
Once I covered the whole head I added bith of ripped up book page onto the surface.
I was surprised at the end result that it did have a papery quality to it. However it was also quite shiney due to the application of the latex so I would like to test this head under camera to see if it does look too shiney.
 
I have started to test how I will skin my puppet. As I dicovered from animation testing that the armature with the 0.9mm wire is of new use I am using this for the skinning so I can continue to animate with the good armature.
I had some tights material in a grainy grey colour that I liked and would animate well which I have attached to one of the legs. This works well with movement and is tight to the leg which is good as I want him to look as slender as possible.
I tried a stretchy wool material on the right hand arm which I had in mind for his jacket, however this was harder to work with and was therefore harder to get tight to his arm alike to the material on the leg.
On his left arm I tried wrapping sporting injury foam dipped in latex, however this also appeared bulkier than the leg material aswell.

Currently I am thinking I might keep the material on the leg and get a similar material but in a different colour for the top half.
 
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.
 
After making my prototype head armature in the workshop, I thought I would have a quick go at making one that was in an attempted style of my Librarian. This was handy as I got to have a go at making a VERY small head armature that would be around the size I would need to use in the actual final puppet. I had to admit this was a very rushed trial so the aesthetic quality isn't as much of a success as I would have hoped to achieve.



However despite this fact I think I am coming to the realisation that in using foam and latex to create a moving head (brow and jaw) it is detracting from the look I am trying to achieve: angular and sharp. I need to explore other materials (but might give this another go in less rushed circumstance just to make sure)!
 
I have also attended another workshop to make a head with armature prototype. The design for this wasn't based on the Librarian, the idea was just to make a head in the time of the workshop so that we may apply it to our own character if we so wished. We were given a standard and basic lightweight head with a wire jaw and brow which we then built upon with foam and latex to create a face.

Here's how:
Using fine foam dipped in latex, cover the armature and lightweight core with a single layer, including a whole piece of foam that covers the gap between the wire jaw and the 'skull' to create the 'flesh'.
Add foam in bulk where needed, for example the cheeks, using fine scissors you can cut them into shape once the latex has set.
Adding more layers to create facial shape.
Using fine bits of foam rolled into strips I have created detailing on each side of the head to look like the ears.
Basic facial shape in place.


Once everything has been covered, including the eyes and the teeth, using a thicker piece of foam glue this to the top flat area of the head in a square block. Once the glue has set you can then shape the foam to look like a skull.
Cut a slit where the mouth should be to reveal the teeeth and then shape in a mouth.

Cut away the foam covering the eyes.

Ear detail.


Layer of fine foam onto of ear detail to create the appearance of the ear jutting out of the side of the head.
The finishing touches: using a coctail stick I applied latex straight onto the head in areas that needed building up further.