Covering the Structure
Once the skeleton of Totoro was complete, I noticed that his shape was not symmetrical, and some of the rings were far too large. Fortunately, I had secured the rings with masking tape, which was very easy to remove. It was then a simple matter of pulling each of the problem rings in and wrapping with fresh tape. I also had issues with the gaffer tape supports between the rings giving way, causing the rings to drop and become lopsided. Where tape had given way, I ended up applying a new piece of tape that wrapped around the ring onto itself at both ends.
I did work out a very efficient way to cut the gaffer tape in half to make thin strips. I would tear off the required length and place it sticky side down on a self healing cutting mat. I then used an X-Acto blade to cut down the middle of the tape. It was then very easy to remove the tape from the mat and use the sections of tape on Totoro’s skeleton.
The next step was to start covering the skeleton with thin fabric. I used an old sheet since I am trying to keep costs down, and recycle materials that I already have. All of the darts were sewn using sewing machine, and I hand stitched the final opening closed. So my Totoro has a interior of Ancient Egyptian patterned sheets!