I am working on a rat fur suit that will be worn on stage. Many different people will wear it over the course of the show.
In the past I've built a fur suit dog with a hockey helmet as the base of the head with carved foam rubber for the head.
I've been reading a lot and hear good things about the balaclava construction for heads.
Here's is the background and requirements.
1) I want a sturdy head that can stand up to professional use and demands of various wearers and a traveling show.
2) It will only be worn on stage for 15-25 min. per show. So, comfort and weight are always important but this is not going to be worn outdoors, all day long, nor in a physically demanding role.
3) It will need to fit males and females of very different sizes. As we are on the road the person in the costume may change at every venue.
4) Great looks is the most important element (over ease of construction, cost, or comfort).
5) I do not need an articulated jaw. The person wearing the costume will not need to talk or simulate talking. Articulated jaw is okay but not required.
6) The whole character is for stage and will be built to look "larger than life" meaning the head will be large and cartoonish rather than in proportion to an anthropomorphic rat body.
Here is my question. Given the above guidelines, how would you choose to construct the head; a helmet base, balaclava, or something else (and if so what else)?
Also, I'm interested in any advice or tips that I'm too dumb to even know to ask about.
Thank you in advance. I am so glad to be a part of this wonderful online community.