I had to polish every inch of the hard dense foam with a dremel tool to get the surface of the foam to be less sponge looking. Then I smoothed out the tooling marks by adding a little heat.
I have really enjoyed working on this puppet, because I haven't had to sew anything. It's been a nice change of pace to paint the foam. The results are a little more instant, and if I don't like the way a color came out I just paint over it easy as you please. The puppet has been a delightful challenge, learning to make foam look like metal. I've been very satisfied with the results, though I still have a long way to go.