The most unique challenge for most people still seems to be making the head forms. I saw a lot of bad advice on the internet in 2004 when we first created this site (we started building mascots professionally in the 90's), so I wrote this note for people who dug a little deeper, and were willing to work a little harder to find mascot making "secrets". Here's the original message:
It's really hard to make things symmetrical when you make a head by chopping of blocks of foam. It takes forever, too! This is a note that I wrote someone a few years ago that shows the basic idea of patterning flat foam sheets. If you make the basic head shape first, you'll have a stable base to glue a muzzle on...
Good luck on your project!