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Time to start foaming! In my personal opinion, the muzzle is the most important piece to get the shape correct right off the bat otherwise it could throw the whole head off later on, (i.e. crooked muzzle, no smile, lack of expression, uncomfortable fit against your face). So you have to really sculpt the shape of the muzzle before attaching it instead of just slapping on chunks of foam then going back and sculpting.

To start off and to get the basic shape, take your jawset (if you are using one) and trace it to the 4in thick foam to ensure that the muzzle will fit the jawset once everything is said and done (otherwise just draw the size of what you want for the bottom jaw). Then trace around the jawset mark to the approximant size of what you would like the bottom jaw to be, then around that trace the size of the upper muzzle. By doing this you ensure the upper half of the muzzle will fit nicely over the lower jaw once its made. Just imagine it like your mapping it out in a way. Then using an electric turkey carver cut out your muzzle, now its time to shape it down further.

First, cut a notch at the base of the muzzle where it would lay against your nose. Then under it cut a slope on both sides, this will give it a “smile appearance” in the end, and then hollow out the inside where the bottom jaw would lay against it in the future. The shape you will need is difficult to explain, so be sure to really look at the picture and you can see what I am trying to describe. This is the desired shape you want.