Made the ears today and went out and bought some hard wear for the jaw. These ears will have a hinge on them and will be movable. Main structure is constructed from 1/8" foam core, I ran wire around the outside of the ear and then covered with more foam to make a nice strong shape for the ears. Next with these I'll need to work on the rear hinge mount. The blue poster board I taped on the jaw shows where foam will be placed to create the correct jaw line.