His name is Alberto, he is an old ranch hand.
Here are some photos of the process.
I got some very helpful templates from the puppet project.com
Designed cut and sewed the little overally nuggets + Plaid T and stuffed them with a little stuffing to give him some extra dimension.
This is the puppet inside out. You can see the mouthplate construction here.
Styrofoam eyeballs wrapped with felt, a cotton-stuffed nose, and the wire & string beard rigging.
After hot gluing on all of the hair.
-Then you have yourself a puppet.