A body suit is the fabricFabric is the outer surface of a puppet — the skin, the cl... More body of a puppet — the part below the head that gives the character a shape, hides the performer’s arm, and carries whatever clothing goes over it.
It is not a body
It is the illusion of one. Underneath is a forearm and, in a rod puppetA rod puppet is operated from below by rods running up into ..., nothing at all. The suit’s job is to suggest shoulders, a chest and a posture where none exist.
Shoulders are the whole trick
A tube of fabric hanging from a head reads as a sock. A shaped shoulder line — usually a foamFoam is the structural material most soft puppets are built ... More or batting former across the top of the body — instantly reads as a torso. It is the highest-value hour in the entire build.
Arm attachment
Arms hang from the shoulder former rather than from the fabric itself, or they pull the body out of shape within a few performances. For rod puppets the attachment point also has to take the load of the rod without tearing.
Length and the performer
The suit has to be long enough to cover the forearm to the elbow at full extension, and to keep covering it when the puppet is raised. Measure with the arm up, not down.
Material
FleeceFleece is the knit fabric used as the outer skin on most mod... More for exposed body, since it matches the head. Lightweight woven or knit where clothing goes over the top, since bulk under a costume shows.
Weight from the bottom
A little weight at the base of the suit makes it hang properly rather than floating. A small bag of poly pellets sewn in low does it.
The hack: build the shoulder former before you sew anything else, then drape the fabric over it. Working the other way round means guessing at a shape you cannot see.