Plastic spreaders (e.g., Bondo® brand or putty knife)Ĭut-in brush (for large areas can be substituted for a chip brush)Ĭutting mat (optional the larger the better though) Various nuts, bolts, washers and lock washers Plumbers epoxy (not always in the plumbers aisle, go figure) Wood dowel or metal (mouth mechanism handle) Mod Podge® Clear Acrylic Sealer, Gloss (or any other brand gloss sealer for acrylic) Sandpaper (60, 80, 120 grit, etc.) – Block sander or single sheetsīondo® (or any other type automotive body filler)īondo® glazing and spot putty (for filler pinholes)Īcrylic paint (red, orange, white, blue, black, and brown) Hot glue sticks (order online, much cheaper) They’re used to these calls from theatres. It is very hard on your hands and fingers over time.) Call up or email your local appliance store(s) and see if they have a bin that you can rummage through to get a lot of different kinds of cardboard free. You can purchase anywhere: online, in art stores, or hardware stores.) Don’t let this materials list stop you from your build if you feel it is too much! You do not have to use all of these materials to fabricate a fun, functional, and nice looking puppet.Ī lot of corregated cardboard! (Do not use cardboard from an appliance, like a refrigerator. Materials Used: (The links are for visual identification purposes only. Now, with that all aside, let's build a puppet! I will also give you some hints, warnings, and lesson learned that might help you along the way. I didn't have enough time to build (not hard to build), but I did regret not making it. I also didn't make Zazu have a mouth mechanism to simulate talking. I will do my best to illustrate what was done in the fabrication process. I took several photos during this build, but many intermediate photos are missing because I didn't realize I would be writing a tutorial one day. A fabrication of this nature can be time consuming (especially with the feathers!), but it is very rewarding in the end seeing the children's faces perform with them and seeing your work come to life in front of an audience. But Zazu seems to be holding up 2 plus years later. Having said that, I wouldn't recommend using cardboard for puppet designs. Not knowing where to start learning how to fabricate a puppet, I found many Instructables (a special shout out to RickGyver) that helped using cardboard as the structure and more. I am slowly building my skills over the years and hopefully this Instructable will help you attain your goals and/or passion for fabricating as well. I have over 33 years in multimedia and design and always wanted to get into this profession since I was young seeing the creepy animatronic figures at the "Hall of Presidents" at Walt Disney World. I actually took on way more than I should have by creating most of the characters in the production. and Zazu were my gateway into theatre and entertainment projects creating puppets, props, costumes, and traditional and digital sets. In total took about 2 days to get all the peices to fit properly.The Lion King Jr. The tail was a wire hanger with card board at the ends for no poke accidents haha.As for shoes we covered old slip ons with brown felt. The pants and shirt were seperate to make bathroom use easy. We painted it to match the colors to be true to the movie as well as added some hair to the chin area. We purchased a baboon mask online and made changes to resemble Rafiki more. The holiday medal nuts we attached to the end of the stick were bells which gave it a similar sound like rafikis stick has in the movie. We bought Rafiki’s stick at a craft store and painted brown and well as the hanging decorations. We took orange paint and painted shoes we no longer used took about a day to complete. In total Zazu took about 1-2 hours for wings and head piece to dry. We made the beak from a thick cirlcle of felt and cut it to size.įor the beanie we used smaller pieces of felt and cut to size to make eyes and small hairs. Zazu is made out of different color felts from a craft store and clothing articles we already had. It took about 2-3 days to make these Zazu and Rafiki costumes.
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