Large Shark Puppet help.
So I had this idea for a large puppet...Shark Cosplaying Lady Dimitrescu...It's stupid, I know. I have a vague idea of what I want it to do/operate. I’m thinking cable controls fed through a custom wagon handle. The handle in the concept art here is in the front but I plan to make the handle in the back like a push cart that way the head is in view. The idea is its a miserable, fat shark. So movements for the most part will be minimal. The eyes squint and blink and the head can slightly move left/right like a real shark. The Jaw opening would be the biggest movement.
I don't have a lot of space so I don't want to make Bruce from Jaws, but sizable enough so it impresses. Any size suggestions would be appreciated.
First question is, what materials would you reccomend for the frame? I know that if its big, it needs to be strong. Since I'll be using a red wagon to move it, I won't be lifting it. I'm thinking bike cables for the eyelids. I will need a stronger mech for his jaw/head turn. Keeping in mind, the wagon handle will be made from a hollow PVC tube with the control cables threaded through, and triggers on the wagon handle.
Last connundrum is the skin. He's cartoony but somewhat real looking. I need a method and material that can save space and won't break the bank. Now, with latex, it requires a plaster mold, but I hate working with plaster, and to mold a giant shark with a plaster mold will be too big and too expensive.
Silicone is more expensive but since its a chemical cure and doesen't require a porus mold (to my knowledge) to cure, I could possibly 3D print a mold in pieces?
I've built rubber puppets, I've built mechanical puppets, but never one this big.
Anyone who’s made large puppets like I'm describing, let me know any tips. Thanks!