The pattern can be downloaded at the following link: http://www.scribd.com/shelf
I am using an old t-shirt. It is better to use an ADULT-LARGE size so you have enough for the whole pattern.
PREPARING THE FABRIC: Cut out the pattern leaving a 1cm seam all around. However, take note that you need only to leave 1/2 cm seam around the fingers. Then sew all around leaving the mouth open as shown in B. Take note to cut as close to the valley between the fingers as possible before turning them out (shown in A).
THE MOUTH PIECE: Trace out the mouth pattern on a piece of hard card(A). I am using card from a box for this. Trace another one on a piece of black felt and glue the two pieces together(B). Lightly cut a line across the card(C) to make it bendable as shown in D.
THE MOUTH: Apply glue along the edge around the mouth piece on the black felt side and place the edge of the mouth fabric over the edge where the glue is applied(B and C). Cut the foam piece for the head as shown in D (more details in the pic below).
THE HEAD: Apply cement glue along the two inside edges. Use a piece of hard card to spread the glue on both edges and leave it for a min before placing the two edges together (B and C). Then gather the fabric together so it is easier to insert the foam inside the head over the upper jaw.
THE BODY INSERT: Trace out the pattern for the foam body and cut it out with a sharp blade (A and B). Apply cement glue to the two ends and join them together(C and D).
Insert the ready foam body into the sewn fabric.
THE TONGUE: Trace out the tongue patterns on a piece of bright-colored felt(B). Glue them to the inside of the mouth piece as shown in C. Cut out a piece of the lower jaw from foam(D) to insert to the lower jaw.
THE ARMS: Fill both arms with poly fiber(A). Sew a line across half way where the elbow joint(B) is so the arms can be bent(C). Gather the opening and sew them closed, taking care to push the edges inside(D).
Apply glue to the end of arm where it attaches to the shoulder(C).
THE FACE: I cut a ping pong ball into halves and wrap one half in a piece of fabric and glue it to the face near to the mouth and glue two googly eyes to complete the face(A). Take note of the difference it will make when the eyes are placed closer together(B) and further apart(D). Use furry material or wool for the hair.
Dress it and you have a simple mouth puppet ready for the show!