There comes a time in every Muppet’s life when a cosmetic touch-up is needed, and sometimes they must be replaced altogether. Most Muppets are replaced every five years; Cookie Monster, Bert, Ernie, Grover, and Kermit are replaced every ten to twelve. As for our friend Big Bird, he’s given an overhaul at the end of every season, and his feathers are completely replaced every five years. Big Bird is technically envisioned as a large canary, but his costume is made from the feathers of a very different bird – the turkey – in a somewhat tedious process:
Turkey feathers are purchased from a company in the United States, then shipped to China, where the spine of each feather is cut in half to make them more supple.
The feathers are then sent back to the feather company, and bleached and cleaned. Then they’re dyed: the tips a bright yellow, and the part closest to the body a deeper golden.
The feathers are sent to the Muppet Workshop, where they’re separated into grades – A, B, C, D, and E. Each feather has to be in perfect condition and from eight to nine inches long. Only the top three grades of feathers (A, B, and C) are used to make Big Bird’s costume; the rest are discarded.
Muppet builders then hot-glue the feathers onto the base of the costume.