Now that the skeleton is covered with fabric, I used spray adhesive to attach a layer of cotton batting. The purpose of the batting is to disguise the ribs of the skeleton. I then started to cover the batting with the very reasonably priced fur I got from Kmart!
I purchased 14 rolls of fur and had to remove the faux suede backing on each one. Each one was then sewn together using the sewing machine. 4 Blankets sewn together gave me enough fur to make two of the four panels required to make the outer skin of Totoro.
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!
After watching the video by Adam Savage, I used sheets of butchers paper to draw a template of a figure my size so that I could plan the size of the cane rings I would need for my Totoro.
This process took most of the afternoon to work through, but I ended up with 16 ring dimensions. The widest ring is 1m in diameter, which means that the circumference of cane is 3.2 m!
Now that I have a plan, it is time to order the cane. I am ordering the cane from http://www.wickerworks.com.au/. I decided to order a 500 gram bundle of 5mm round core cane which will give me about 50 metres of cane to work with.