Oh goodness. No, I'm not that evil to make him sit there for days. Hypothermia is a good point too.
Yeah, we opted to go with a cast. The more I thought about it, the more I realized it would just be the best option. I can take hours back and forth from doing things to get it just right.
I was really thinking of a plaster cast.. (multiple layers of plaster strips) and then reinforcing it with good glue and possibly even cloth if unnecessary? I really don't want to mess with resin for it though. Like they did -> http://www.craftster.org/forum/index...993#msg3676993
Would I need to buy a tub of plaster in addition to the roll of strips, or are just the strips fine? (I know! So many questions..)
I'm not really sure how I'm going to fit it together yet.. I'll have to look at the pattern deeply and see.
EDIT: You know... those light green sides and lower back look like they're (possibly stretchy) cloth material.. Attaching lightweight cloth to leather??