Theodor's chest and crotch were bulked out using balsa wood, making sure the rigs are accessible. The photo's show the front, back, left and right of the puppet in that order.
The middle section between these two piece of balsa wood was then padded out with styrofoam. The photo's show the front, back, left and right of the puppet in that order.
Theodor's neck was sculpted from plasticine with a piece of K&S running through the middle, a cast was then made of this neck. Once the plaster had hardened a layer of silicon was painted into the mould.
When this layer of silicon was dry Theodor's armature was slotted into place, using the K&S slot in the mould as a guide. Masking tape was used to stop the armature falling to far into the mould, while also reinforcing it in place.
The neck once it had been removed from the mould
The legs and arms were padded out using a thin sheet of foam I'd acquired from packaging.