Grover Replica Puppet Build
Replica Builds, Sesame StreetThis is a quick image guide on how I built my Grover replica. I tried to provide a lot of pictures for you to give you ideas on how you can build your own. Enjoy and feel free to ask me anything.
Foam body and skull patterns. This includes the skull and the lower jaw.

Using contact cement to glue the foam pieces together.

Creating mouth plate. The mouth plate is only hinged by the fabric vs tape as it allows Grover to have a loose jaw.


Added individual finger holders for better control.



Attatched mouth plate to upper foam skull and lower foam jaw.



Created and dyed with Rit red dye the lips out of antron fleece and foam.

Sew head and body pieces together.


Trimmed fur.

Casted eyes with white molding plastic. Used plastic spoons as the mold.

Mocking up facial features.

Used Rit dye to dye antron fleece for nose. Covered styrofoam egg with fleece for nose.

Created hand rods with wood dowels, beaded arms, and foam hands. Combined to body of puppet with doll joints. Final trim.







Check out my other write up if you want to make this into a Super Grover!

Are you going to list more of your puppets on eBay?
Congratulations ššš
This is an awesome build!!
I started building Elmo using the information on your build, and Iām curious is the body for Grover the same as for Elmo?
Also wondering about the head pattern, is that something you drafted up or is that a pattern I could get somewhere?
Thank you so much!
Grover’s body is from the mostro pattern, so its the same as Elmo’s. His head is from etsy, but it needs to be scaled down a bit since you are using fur instead of fleece. Here is the link:
Etsy