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Stylized fursuits and digitigrade patterns?

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Hey all, I've got two questions and I need some input.

Stylized fursuits:
Currently I have one in-use toony fursuit of my character, here. She's cute and all... But I'd like a more "intriguing" fursuit. I used to have a realistic fursuit head (which was destroyed) and a flirty TOONY head (also destroyed). My inspiration comes from this head, and I'm looking build this second head on a DVC base with a face similar to this. Any tips on altering a fursuit face just enough so it'd be like that?

Digitigrade patterns:
My friend is commissioning me for lower parts. The feet and tail will be a breeze... It's just the legs I'm a little confused on. I've done digitigrade padding twice in the past and although it was wonky, it worked. However, the foam was very bulky and things heated up fast. I don't want my friend heating up quickly, he's very active in his fursuit.
My idea was to use either 1/2" or 1" foam and make a paper pattern, transfer it to the foam, hot glue pieces together and attach to sweatpants before furring it. No extreme bulk, the shape is there and it'll be easy to wear. Does that sound realistic or a waste of money?

Thanks!

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