Having a project of this size was a big challenge. The first challenge was finding time to work on it. While working on this project, I was on the LTOTS's touring show playing the part of Merlin the Magician, doing as many as 11 shows a week. During this time I was also teaching 3 separate maskmaking classes and a prosthetics class. So with limited time, I decided to focus my design around the head of the puppet. I figured the bodies, except for the two considered "portly," would remain fairly similar in shape, and only vary in size. I would rely on the costumes to help complete the uniqueness of the bodies.

I quickly sketched a drawing for each of the characters on my list. Some of the puppets would play as many as 3 different characters. As I designed the heads, I was looking for a variety of shapes and sizes. For example, I specifically gave Bob a long thin face with big ears, and his wife a rounder, more chubby look. I wanted to cash in on the visual comedic potential effect of having such different shaped husband and wife.