Hello Tom, I use mostly Papier-mache' or latex heads these days, Chris has it right, Papier would be the best material for you to start with. The way I do it is to use Kitchen roll and the 'Proper' PVA. (The sort you get from builder's merchants, not the watered-down stuff from craft shops) I tear the kitchen roll into strips lengthwise. If you try tearing it you will find that it only rips cleanly one way, which is what gives it the strength. Then I mix some of the pva with a little water,(Not too much, just enough to thin it slightly) in one of those shallow trays they use in take-aways, although any shallow tray will do. I then make a tube to fit round my 'Head' fingers,(Usually out of a toilet roll centre, squashed to fit over a bit of cloth, and wrapped with masking tape.) You then pull the strips of kitchen roll through the pva over the edge of the tray, so that it scrapes off the excess, and build up your head in strips wrapped around the 'neck' tube, crossing them over each other, a bit like weaving. (This builds the strength) This is where you need a bit of patience, as you have to be careful not to put too many layers on at once, but allow them to dry off after 3 or 4 layers, otherwise they take too long to dry, and shrink a lot. I get round this by doing a few heads at once. When you have them to a finished shape, (You can squidge up strips to make features, but cover them with longer strips to hold them in place) mix a bit of the pva with flour, to a thick paste, (Roughly the consistency of double cream) and dip the whole head into it, so it is completely covered, then let it dry. (I stand them on bottle necks to drain, - This is the messy bit! If you do this a couple of times, it will give you a good, hard, surface to paint on.Then when you've finished painting, give them a couple of coats of polyurethene varnish (Matt or satin) to finish. They should last you for years, needing only bits of re-paints. Best of luck, and above all, enjoy!-Remember, they will be YOUR characters, so don't be too bothered about copying anyone elses!!