Construction Details:

I settled on using a modified kid's pool toy for the understructure: this involved a lot of cutting and re-gluing of the original toy (literally about 1/2 of the original ball).

The next problem to tackle was his fuzzy self. Lynette and I searched high and low for a shag-fur that would be poofy enough to achieve the look. After trying a number of fake furs, we went in another direction: blue clown wigs. Wading through the variety (mostly awful) of wigs was more difficult than the cutting-and-sewing-together of all the wigs (39 wigs in total). The result (in our opinion) was worth it: he's totally fuzzy.

His boots were made from a modified "Pimp Shoe". I added a semi-rigid sheet foam to build them up and Lynette covered them with the appropriate spandex colors.

Blue Meanie Boss's hands were also a challenge: they're so huge, but they needed to be able to wiggle and hold things (like a cell phone). I built up some hollow foam sausages and added finger extensions to all of them so that I could move them with some dexterity. They were also made large enough so that I could pull my hands out and get them back in again quickly for a gag in the skit.

His head was another non-Euclidean challenge. Studying the film and frame grabs, I think I did a good job getting his head right. Vision is limited, but that was a sacrifice made to get the head the proper size and shape. Lynette covered his head and hands with a blue fleece; his lips and antennae-hat were covered in spandex. His head and teeth are carved and coated evac foam. His pants are spandex, fitted with foam to give them body.

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