How To Make A Latex Rubber Arm and Rod Hand Puppet Head

Building a latex rubber puppet is not difficult. Latex creates some opportunities to make puppet characters that fleece and foam do not.

There are eight steps to building a latex puppet head.

1. Sculpting the head
2. Casting the head
3. Pouring the rubber
4. Preparing the head for painting
5. Painting the head
6. Wigging the head
7. Building the body
8. Costuming the puppet

MATERIALS NEEDED:

• Hydrocal – this is a quick setting plaster. It sets harder than plaster of Paris
• Mask Making Latex – you will need roughly 2 1/2 cups. It should have a medium viscosity.
• Acrylic Paints – you will need black and white and then other colors of your choice
• Contact Cement – You will need contact cement to attach things to the latex head
• Brushes – Use acrylic brushes. Size numbers 2,4 and 6 are excellent choices for painting the head
• Electric heater with fan – This is optional but can speed up drying time for the latex rubber

The eight steps are sculpting the head, casting the head, pouring the rubber, preparing the head for painting, painting the head, wigging, building the body end, costuming.

Detailed instructions are available and each section will contain a link to those instructions.

STEP 1: SCULPTING THE HEAD

For this step you will need 5 lb of oil-based clay, such as Plasticene, sculpting tools, a kitchen knife, rubbing alcohol, a brush, a piece of light card and scissors.

This is the most important step in building a latex puppet head. Take your time and you will do fine. If something doesn’t look right, you can always do it over.

This is the step where you define and refine your character.

You may want to pick up a few library books on sculpting. With a little practice, you can make what you want.

Be sure to look at your sculpture from all angles. Your puppet needs to look as good from the sides as from the front.

STEP BY STEP GUIDE TO SCULPTING YOUR PUPPET HEAD IN CLAY: CLICK HERE

STEP 2: CASTING THE HEAD

For casting the head, you will need plaster, water, a bucket for mixing,
a cardboard box, an electric heater (optional).

The back of the head of the clay sculpture is cot off to allow the sculpture to lay flat in the cardboard box.

Plaster is poured over the sculpture and allowed to dry. An electric heater may be used to speed drying.

Once the plaster is solidly set, the mold is removed from the box and the clay is removed. The inside of the mold is then rinsed with water and is now ready to cast the latex head.

STEP 3: POURING THE RUBBER

The mask-making latex is poured into the mold. Fill the mold and rotate the mold to get latex into all the nooks and crannies. You want the fine details of your sculpture to be filled with latex. Let it sit for 5 to 10 minutes.

Pour the latex out of the mold and back into its container. Latex will remain in the mold. Allow this to dry. An electric heater may be used to speed up the drying process.

Repeat the above process 3-4 times. Each time you do this, your puppet head will get thicker and thicker. You want a nice thickness for a durable puppet.

You may now remove the head from the mold. Start y shaking the mold and this will release most of the head. Then carefully peel out the rest of the head.

TIP: Before pouring the first layer of latex, you may want to color the latex with water-soluble acrylic paint. Only the first layer needs to be colored.

STEP 4: PREPARING THE HEAD FOR PAINTING

After you remove the head from the mold, you will need to prepare it for painting. Rinse any plaster that remains from the head.

Trim away any excess latex from the head. Cut the neck open so your hand can come up from the bottom.

You will need to fill in the hole where you cut away the back of the head to lay it in the box. You can use 1/2″ upholstery foam and make a shape like you would a foam head puppet.

You may prefer to get a 4″ cube of polyfoam and trim it down to shape with scissors. Attach your head piece with contact cement.

STEP 5: PAINTING THE HEAD

To paint your head, use acrylic water-soluble paints. You can airbrush or hand brush your puppet head.

You can do a base coat all over the head and then add to that your darker and lighter skin tones.

You want to put the paint on in thin layers. Dip your brush in water to thin the paint a little as you apply it. You don’t want to put it on thick because the rubber is flexible and the paint dries like plastic, and, it has a tendency to flex off it applied too thick.

STEP 6: WIGGING THE HEAD

You have your painted head and you’re going to wig it. So what you need are a variety of wigging materials to choose from.

You can use an actual wig, which can sometimes be found at thrift stores or you can use costume wigs.

You can also use feathers, fake fur, yarn or angora wool.

Additionally, you can add eyeglasses, jewelry, fur eyebrows, moustaches and beards at this step.

STEP 7: BUILDING THE BODY

Now to make a foam rubber body and arms. And make rods for the arms, making the body. You need:

• One inch thick foam sheets
• Contact cement
• Straight pins
• Coat hangers for arm rods

The basic body will be a tube of foam roughly 12 inches tall. After you make the tube, cut 2 V-shaped notches directly across from each other on what will be the top of the body.

The notches should be about 1 inch wide and in the shape of an equilateral triangle, all sides being one inch.

Using contact cement, glue the notches closed. This will give you a bit of a taper at the top of the body. Your arms will be attached at the notches.

Make the arms of your puppet by making tubes from the foam. The tubes should be roughly 1″ in diameter. The arms should be the same length as the body.

Put a notch in the arm tubes where the elbow should be. This will allow your arms to bend. Attach the arms to the body with contact cement. You may want to taper the top of the arm before attaching for a better fit.

Attach the hands to the arms. FOR COMPLETE INSTRUCTIONS ON MAKING PROFESSIONAL HANDS AND ARM RODDS, PLEASE GO HERE.

STEP 8: COSTUMING THE PUPPET

You may cover your puppet body with fabric if desired. If you will be putting clothing on your puppet, a fabric body covering may not be needed. Only exposed parts of the body need to be covered with fabric.

You can make your own puppet clothes or you may purchase toddlers clothing. Thrift stores have a wide selection of 18 months to 2T clothes you can choose from.

If you made an animal puppet, you may choose to cover the puppet with fur and you will not need clothing.

STEP BY STEP GUIDE TO SCULPTING YOUR PUPPET HEAD IN CLAY: CLICK HERE