I was told Gary couldn't be made because "You can't make a mould of something with feathers!" and that I shouldn't bother trying, it would be a waste of my time.
Anyway...
Gary was made by making a mold of a taxdermied albatross out of silicone with a plaster outer case mold.
I then hand roto-molded him using a polyurethane resin.
Gary's is wired using l.e.d.s