I'm finally starting to make my fursuit! I'm only doing a partial for now, starting with the head. Instead of messing with flat foam and making the suit look cartoony, out of proportion and, well, normal, I'm opting for a more realistic approach. It all started with a taxidermy lion's head (roughly $40 after shipping). No, I'm not a lion, but it's the closest in shape and size as I'm going to get.
From there, I took an exacto knife and hacked away at the head from the back forward, proceeding to both hollow the form and taking a nice chunk out of my thumb. Please, when you use knives, be careful! I am an expert with sculpture and yet I still manage to get bloody from time to time. Anyway, I was concerned that the foam wasn't going to be resilient enough to hold up in the long run, but after a series of stress tests (aka, me beating on the hollowed foam until satisfied) it works out great. I'm still going to have to do some major sanding and refining to the foam piece before moving on, but that's all boring technical stuff. Also, the chin thing. That needs work. You'll see more and better images later.
Oh! In the other post, I forgot to mention: I had to cut an inch out of the muzzle so that it looked less like a lion and more like a domestic cat. Hot glue works just fine to put it all back together without melting the stuff. Later on, I'll be hot gluing all the fur on (but don't expect that post for a while - I still have to order the stuff.)