I am building the egg shells for Honk. Our "Ugly" is 10th grade, but the ducklings are mostly upper elementary to early Jr High. This is an arts school, and we do want to do significant choreography.

If it were not for budget constraints, I think I would have used polyethylene foam, and a combination of vacuum forming and gluing parts together. I think that would be an idea appearance, and be very tough.

I am planning on using paper mâché. I should be able to use some families with kids for the labor. The results wold be covered in some stretch cotton that would be glued to the surface, to give a relatively smooth finish. The foundation for doing the mâché would be a pair of beach balls, that would be taped together so that they somewhat squish into each other. And though the resulting shape is not ideal, I can't think of any other easy way to get a more elliptical shape.

The bottom would be cut-out for them to both enter from behind, and for their legs to be out to dance. I don't think we will attempt to put arms out the sides. I am concerned about the structural integrity of the mâché.

I considering embedding magnets in the perimeter of the head opening, so that they can push it out at some point. I doubt that wearing them as hats will work well, since they will tend to fall off very easily. Nor do I think it wold be viable for them to enter the shell, and then put a strap around their heads.

The overall size for the larger shell for Honk, will be 21" Dia by 26" Tall. And the smaller ones will be 18" x 22". Attached is a sketch I did in a CAD program. It shows the ideal egg shape on the outside, and some dashed lines inside to show the edges of the beach balls.

I haven't done mâché myself, since elementary school. So, I wanted to do a reality check from someone who has more experience. Here is my current formula...

PVA Glue, diluted by half.
Strips of news paper.

The vinyl of the beach balls will probably separate from the mâché easily. I will tape them together using packaging tape, so that will also probably separate easily. This tape will cover the entire bridge area between the two partially inflated beach balls.

Apply three coats at a time then let it dry overnight. Get a total of 9 coats.

The main opining at the bottom should not be covered wit mâché. Let the air out of the large beach ball, and then it can be removed, along with the small beach ball. Cut the top off with scissors and also cut the bottom hole to the desired shape and size. Add more mâché around all the cut edges to strengthen them.

Finally, I will cover them in stretch cotton jersey. First a light coat of glue is added, then the cloth will be stretched over the shell, and folded over the edges. Hopefully it will stretch enough to cover over half of the front, and then any darts or seams can be cut and simply glued down.

There will be a pair of straps fastened inside, though I don't know how best to fasten them so that the attachment method does not show outside. Perhaps a fastening device can be added while it is being mâchéd. Perhaps a D-Ring with a strip of cloth is first laid down on the beach ball. Then, we mâché over parts of it, but lift the cloth strips to put the mâché under them. After a few layers, lay the cloth strips down, and then do the mâché over them.

Is there anything I am overlooking or other advice?

-Joe

Edited by jdunfee12 - 6/30/16 at 7:09pm