I'm working on a new one-man storytelling show and I have all of my remote characters except one: A clock. A grandfather or cuckoo clock that keeps actual time and verbally alerts the storyteller to the various phases of the show. I plan on building this critter, but I have a few questions I'd like to ask you experts before I proceed:

1) My plans call for constructing the prop from foam with a faux wood finish for ease of transport. Do you have a stiff foam or other lightweight yet sturdy material suggestion? I'd really rather stay away from latex.

2) The figure's speaking ability must either be controllable remotely from the storyteller's chair or a programmable animatronic that will activate at specified intervals. I'm familiar with speech chips and I have a random winker and a robotic sensor that will allow the levered eyes to follow the storyteller's movement around the stage to display "interest."

3) The mouth is a simple "card through slot" arrangement similar to the Axtell Drawing Board. I plan to use a simple joystick push-pull servo unless you have a better suggestion.

The clock would be operated across a small stage from the storyteller. The storyteller will generally be seated in a classic wood rocking chair.

My goal is to create interactive characters in the show without relying on a behind-the-scenes puppeteer. Any advice would be greatly appreciated from you robotic or RC pros! I am a total robotic/RC novice - but, I'm learning FAST! Thanks!

One way of making a very light but also very strong foam structure is to make a composite sandwich. This is a core of styrofoam with fiberglass and epoxy on both sides. You could make it even lighter by using carbon fiber but it is much more expensive and more difficult to work with. Search on "composite construction" and you should find info. youtube videos are also available. A good book on the topic is "Advanced Composite Techniques". Bluepoint engineering has animatronic kits and parts.

You know, Oliver, I worked one summer in a fiberglass boat shop on Lake Erie - and the thought of composites never entered my mind. Thanks!

How have you been getting on with this?